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DANA SPICER PACCAR 220ev, Troubleshooting Manual


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294 

Troubleshooting 

Is error F0059 or F0060, 

F0109 or F0110 displayed on 

the HMI?

Yes

Refer to the specific error 

troubleshooting tree.

HMI displays or logs

Fault code F0097  and  Fault reason 9

Fault code F0098  and  Fault reason 9

Yes

No

Yes

No

Complete

Did the fault clear 

during normal 

operation?

Did the error occur under 

extreme conditions: Max speed, 

Max torque, steep uphill/

downhill, extremely hot 

temperature?

Let the truck cool down for 2 hours 

parked outside not under the sun 

with the ignition switched OFF.

No

Continued on next page

 

Summary of Contents for SPICER PACCAR 220ev

Page 1: ...ECTS 0300 October 2022 Models 220ev K270e K370e DOC00015340 PACCAR Electrified Chassis Troubleshooting Guide...

Page 2: ...ing procedures that could cause serious injury or even death Failure to follow these warnings could also cause equipment or property damage The alert will identify a hazard how to avoid it and the pro...

Page 3: ...protective equipment PPE when working with high voltage HV equipment Warning The high voltage cables must be shielded and colored orange The high voltage and level of current delivered by these syste...

Page 4: ...turer s instructions If the fire extinguisher has been used it must be replaced with a new fire extinguisher or refilled according to the manufacturer s instructions before the truck can be returned t...

Page 5: ...s operate on 12V When replacing or fitting electrical or electronic components always verify that they are suitable for the system voltage LV Batteries Warning Always disconnect the battery negative g...

Page 6: ...itive battery terminal and any other metal on the vehicle at the same time Remove metal jewelry and avoid leaning over the LV battery Caution Using higher voltage booster for the LV batteries will cau...

Page 7: ...ault Reasons 14 Fault Log 14 Operational Data 14 Multimeter 15 Troubleshooting Tips 16 Troubleshooting 17 How to Use This Guide 17 ESS 19 Charging System 161 Propulsion System 270 Brake System 325 DCD...

Page 8: ...ason 0x232C01 370 Fault Reason 0x232D09 0x232E09 371 Fault Reason 0x232F01 0x233001 372 Fault Reason 0x234209 374 Fault Reason 0x234309 0x234409 0x234509 375 Fault Reason 0x23480A 0x234907 378 Fault R...

Page 9: ...ason 2 37 Fault Reason 5 37 Fault Reason 11 37 Fault Reason 14 37 Fault Reason 19 38 Fault Reason 21 39 Fault Reason 22 40 Fault Reason 23 41 Fault Reason 25 42 Fault Reason 27 43 Fault Reason 30 44 F...

Page 10: ...F0119 140 F0129 143 F0130 628 F0131 260 F0132 512 F0133 551 F0134 552 F0135 553 F0136 554 F0137 631 F0139 707 F0140 403 F0141 562 F0142 565 F0143 570 F0144 452 F0145 633 F0146 145 F0147 635 F0148 641...

Page 11: ...contact 513 Powertrain cooling pump No contact 685 Radiator Fan 01 no contact 576 Radiator Fan 02 no contact 583 Relay investigation 756 Supervisory Controller no contact 670 Telemetry No Contact OR F...

Page 12: ...tures The vehicle systems include diagnostic capabilities to help identify and solve problems Diagnostics Operational data Diagnostics The Vehicle Control Unit VCU provides self diagnosis during opera...

Page 13: ...m distributes 12V and 24V power throughout the vehicle to power onboard equipment and accessories Power Steering System page 480 The power steering system is an electro hydraulic system which produces...

Page 14: ...resolved The HMI provides an error log which lists all errors raised in chronological order This can be useful when multiple errors are raised at once or when error messages have been cleared from th...

Page 15: ...ided by component specific error messages a multimeter can be used to check sensor and solenoid resistances and to find wiring harness faults The multimeter can be used to check Continuity Ground Brok...

Page 16: ...lone does not indicate a corrected problem An error code is set by a specific fault condition and may be cleared by switching the ignition off and then on It is possible to clear an error message only...

Page 17: ...the unit List of the possible root causes that might be the source of the dysfunctional event determined through the troubleshooting tree List of the possible solutions to each possible cause determin...

Page 18: ...cument such as a supplier manual Subtree Reference Refers the technician to a subtree within this guide Subtrees cover general procedures which may apply to many different errors i e troubleshooting p...

Page 19: ...It uses a chiller and pump to circulate coolant through the battery packs It is one of three coolant loops on the vehicle along with the cooling system and the heater Chiller The chiller uses a refrig...

Page 20: ...ut loop broken or faulty cut loop wiring 6 CAN communication problem 7 Shutdown requested by powertrain safety system 8 Loss of power to MPDM or MPDM internal failure 9 VCU internal failure 1 Replace...

Page 21: ...21 Troubleshooting Connector C53 Connector C76 Connector C93P pin Connector C93S socket Connector C367P pin Connector C367S socket...

Page 22: ...bleshooting tree No Yes No Does the HMI also display MPDM No contact No Yes Refer to the MPDM No contact troubleshooting tree Continued on next page Were you able to find a problem in the CAN A or C n...

Page 23: ...e Investigate relay K007 Is there any evidence of a defect between the pins of the relay Yes Defective relay Replace relay No Continued on next page Does the HMI also display F0058 Yes Refer to error...

Page 24: ...13 Pin 11 Pin 14 Pin 12 Pin 2 Pin 30 C76 C40S Connector pin Connector pin Pin 30 Pin N C40P C50S Connector pin Connector pin Pin N Pin H1 C50P C53 Connector pin Connector pin C9 Pin 5 12V fuse box C14...

Page 25: ...loss No Yes Defective harness Replace harness Is the error still occurring on further key ON or charge cycles No Yes Contact Dana for further investigation Complete Defective supervisory controller Re...

Page 26: ...e vehicle is unable to start The precharge circuit manages the voltage ramp up of the HV system upon startup of the vehicle Precharge ends when the voltage of the HV distribution system reaches 95 of...

Page 27: ...s there still a precharge error on further truck ignitions Yes Complete No Is fuse HV F8 blown or intermittent Yes No Replace fuse HV F8 and contact DANA for investigation on the cause of the blown fu...

Page 28: ...use F8 1 Troubleshoot specific error 2 Resolve CAN communication problem 3 Replace HV fuse F8 This error is raised when the precharge failed error F0017 has occurred more than 3 times and therefore th...

Page 29: ...Yes Refer to CAN investigation subtree Investigate CAN A and CAN D networks Was there a defect on CAN A or CAN D networks Is there still a precharge error on further truck ignitions Yes Complete No W...

Page 30: ...e blown fuse Contact Dana for further investigation Cycle the key in order to be able to retry the pre charge cycle in order to see if the problem is solved Is the error persisting Yes No Complete Obs...

Page 31: ...ible Causes Possible Solutions This error indicates that the Battery TMS has detected an internal failure 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0019 and...

Page 32: ...95 of the ESS voltage The vehicle is then enabled to start If the HV distribution system fails to reach the required threshold within 5 seconds the VCU will flag precharge as failed and the vehicle s...

Page 33: ...ns Battery TMS has detected an input overvoltage overcurrent or internal DC DC converter failure 1 ESS fault 2 Loss of continuity due to defective HV connector or harness 1 Troubleshoot specific error...

Page 34: ...r RT064 from HV junction box Check the connectors for corrosion scorching or physical integrity loss With a multimeter check for continuity between the following points Continuity Resistance is less t...

Page 35: ...the TMS has reported that it has lost communication with the BMS and is no longer receiving control input HMI displays or logs Fault code F0019 and TMS fault reason 48 Does the HMI also display BMS No...

Page 36: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0019 and TMS...

Page 37: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 38: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 39: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 40: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 41: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 42: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 43: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 44: ...system 2 Loss of continuity between chiller and coolant level sensor due to defective LV connector or harness 3 Defective coolant level sensor 1 Resolve leak in ESS cooling system 2 Replace LV connec...

Page 45: ...the batteries and coolant to cool down Turn OFF ignition Turn ignition ON Check the chiller tank for potential leaks Is the chiller tank liquid level low Yes No Check the chiller tank liquid level wi...

Page 46: ...cooling hoses according to the service manual instructions Open the ESS cover panel in order to check for potential leaks in the ESS cooling circuit inside the ESS Are there any leaks in the ESS cool...

Page 47: ...qual to 2ohms C40 Tank C39 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 C40 TMS C46 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 Is there any evidence of a continuity loss Yes No Def...

Page 48: ...n fault 2 Blown MPDM fuse F3 3 Defective MPDM relay K7 4 Blown 24V fuse F1 5 Loss of continuity due to defective LV connector or harness 6 TMS internal failure 1 Troubleshoot specific error 2 Replace...

Page 49: ...the F0086 troubleshooting tree No Inspect fuse F1 from 24V fuse box C20 Does the HMI also display F0008 or F0095 Yes No Refer to the corresponding troubleshooting tree Is fuse F1 blown or intermittent...

Page 50: ...uity Resistance is less than or equal to 2ohms 24V fuse box C20 C40S Terminal Connector pin A1 Pin 14 C40P TMS C45 Connector pin Connector pin Pin 15 Pin 12 Pin 14 Pin 11 Pin 13 Pin 5 C40S TMS C100 Co...

Page 51: ...ect blown fuse F1 from 24V fuse box C20 Replace fuse F1 on 24V fuse box C20 Restart the vehicle Complete Did fuse F1 blow again during test drive No Turn ignition OFF and disconnect F1 from 24V fuse b...

Page 52: ...n Possible Causes Possible Solutions Battery TMS has detected an internal failure of the Battery TMS 1 Battery TMS internal failure 1 Replace Battery TMS HMI displays or logs Fault code F0020 and TMS...

Page 53: ...ssible Solutions TMS has detected a loss of power to its internal DC DC converter 1 ESS fault 2 Loss of continuity due to defective HV connector or harness 1 Troubleshoot specific error 2 Replace HV h...

Page 54: ...or RT064 from HV junction box Check the connector for corrosion scorching or physical integrity loss With a multimeter check for continuity between the following points Continuity Resistance is less t...

Page 55: ...F0038 is also expected to appear If F0022 appears alone there may be a software or VCU error and the technician should contact Dana for further investigation Warning HV system isolation fault can pos...

Page 56: ...a BMS fault reason code indicating the specific reason the limitation was requested The BMS will request limp mode in response to fault reason 28 44 45 47 48 52 54 56 58 60 62 64 66 68 or 70 and will...

Page 57: ...imitation was requested The BMS will request regenerative braking power to be limited to 25 in response to fault reason 52 54 56 58 60 62 64 66 68 or 70 and will request regenerative braking to be dis...

Page 58: ...provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will request regenerative braking power to be limited to 50 in response to fault reason 8 14 25 40...

Page 59: ...terminated It may be possible to resolve a moderate overvoltage by allowing the ESS to rest for a period or by discharging and recharging it If these procedures are unsuccessful the ESS may be defecti...

Page 60: ...7V Yes Contact Dana for further investigation No Turn ON the defrost for 2 hours until the message has disappeared Turn OFF defrost Plug in a level 2 AC charger and fully charge the truck Is the messa...

Page 61: ...ll be disabled If fault reason 6 is raised the BMS will request the vehicle to shut down Note If requested during this procedure to connect the vehicle to a charger a level 2 charger is required Note...

Page 62: ...ccessory mode Access the HMI and check the minimum cell voltage in the ESS diagnostic page Is the error message still displayed on the HMI No Yes Contact Dana for further investigation Plug in only a...

Page 63: ...s that the BMS has detected an extreme undervoltage less than 1 V in one or more cells The BMS will request the vehicle to shut down and charging will be immediately terminated The vehicle will not be...

Page 64: ...ESS Fault reasons 8 9 and 10 are numbered in order of increasing severity If fault reason 8 is raised regenerative braking power will be limited to 50 If fault reason 9 or 10 is raised regenerative b...

Page 65: ...her action Turn the truck back ON in accessory mode Access the HMI and check the minimum cell voltage in the ESS diagnostic page Is the error message still displayed on the HMI No Yes Complete Is erro...

Page 66: ...2 hours until the message has disappeared Plug in a level 2 AC charger and fully charge the truck Turn OFF defrost Is the message reappearing during charge Yes Contact Dana for further investigation N...

Page 67: ...1 Allow ESS to rest then change vehicle to 100 Fault reasons 11 12 and 13 are numbered in order of increasing severity If fault reason 11 is raised the high voltage power will be limited to 50 If fau...

Page 68: ...y mode Access the HMI and check the minimum cell voltage in the ESS diagnostic page Is the error message still displayed on the HMI No Yes Contact Dana for further investigation Plug in a level 2 or l...

Page 69: ...e numbered in order of increasing severity Fault Reason Maximum Cell Temperature 14 140 F 60 C 15 149 F 65 C 16 153 F 67 C If fault reason 14 is raised the high voltage power and regenerative braking...

Page 70: ...tact Yes For safety measure make sure that the truck is parked outside under shade when this occurs Wait 8 hours for the batteries cells to cooldown Does the HMI also display F0045 No Yes Refer to err...

Page 71: ...k the chiller tank liquid level with the reservoir cap open No Refer to the CAN investigation subtree Investigate CAN A and CAN B networks Was a problem found with either CAN A or CAN B network Yes No...

Page 72: ...oling pipes following the maintenance manual instructions Open the ESS cover panel in order to check for potential leaks in the ESS cooling circuit inside the ESS Is there any leak in the ESS cooling...

Page 73: ...ohms Cradle C40 Tank C39 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 Cradle C40 Chiller C46 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 Is there any evidence of a continuity loss Y...

Page 74: ...de F0026 and BMS fault reason 17 Was the vehicle trying to be operated or charged below 35 C No Yes HV batteries do not function below 35 C Complete Move the vehicle to a location where ambient temper...

Page 75: ...Allow ESS to cool down This error indicates that the BMS has detected that the temperature difference between two cells in the ESS is too large Fault reasons 18 19 and 20 are numbered in order of incr...

Page 76: ...FF ignition Turn ignition ON Does the HMI also display F0026 BMS 14 15 16 Yes Refer to the corresponding error troubleshooting tree No Is the error is still being displayed on the HMI intermittently N...

Page 77: ...gh voltage power will be limited to 50 This error could be caused by a short circuit in the HV wiring between the S Box and high voltage junction box If this is the case one or more of Error F0026 BMS...

Page 78: ...eplace blown fuse and Contact DANA for further investigation Are these fault codes also present F0022 F0035 F0036 F0037 or F0051 Reason 14 Yes No Contact Dana for further investigation WARNING Electri...

Page 79: ...in order of increasing severity If fault reason 25 is raised regenerative braking will be limited to 50 power If fault reason 26 or 27 is raised regenerative braking will be disabled Error may occur...

Page 80: ...om Dana 1 ESS internal failure 1 Contact Dana If this error is raised the vehicle will only be able to drive in limp mode and regenerative braking will be disabled Charging will be terminated The vehi...

Page 81: ...ch requires support from Dana 1 ESS internal failure 1 Contact Dana If this error is raised the BMS will request the vehicle to shut down and charging will be terminated The vehicle will not be able t...

Page 82: ...best ESS performance and vehicle range HV batteries must regularly be changed to 100 SOC Vehicle SOC is a calculated valued that drifts over time It is recalibrated only at the end of the charge cycl...

Page 83: ...ent No Yes Complete Plug in only a level 2 AC charger Charge vehicle until charge cycle automatically ends Does the HMI also display F0026 BMS 1 2 3 4 5 6 No Yes Refer to the specific error troublesho...

Page 84: ...raised the high voltage power will be limited to 50 This error may be resolved by connecting the vehicle to a charger and charging the HV batteries to 100 SOC Note For best ESS performance and vehicle...

Page 85: ...nd check the minimum cell voltage in the ESS diagnostic page Is the fault still present No Yes Contact Dana for further investigation Plug in a level 2 or level 3 charger Charge vehicle until charge c...

Page 86: ...h the ESS cooling system The error is triggered when the BMS receives a fault message from the battery thermal management system BTMS or detects that the ESS coolant temperature is abnormal This error...

Page 87: ...the HMI also display F0026 BMS 44 Yes Refer to error F0026 BMS 44 troubleshooting tree No Does the HMI also display F0019 or F0020 Yes Refer to the specific error troubleshooting tree No Refer to the...

Page 88: ...ect causing a cooling reduction Yes No Repair the defect as per the maintenance manual instructions Is there any evidence of a defect causing a cooling reduction Yes No Repair the defect as per the ma...

Page 89: ...is a problem with the heating circuit it is either internal to a battery pack or is within the wiring harness between the S Box and battery pack If the defect is inside one of the battery packs the ba...

Page 90: ...nector investigation subtree With a multimeter measure the resistance between the following pack heater connectors on the battery packs Pack 1 C785 Connector Pin 1 Pin 1 Pack 1 C786 Connector Pin 1 Pi...

Page 91: ...y between the following points on the HV wiring Continuity Resistance is less than or equal to 2ohms S Box C787P Connector Pin 1 Pin 1 Pack 1 C786P Connector Pin 1 Pin 1 S Box C782P Connector Pack 2 C...

Page 92: ...nnector investigation subtree With a multimeter measure the resistance between the following connectors on the battery packs Pack 1 C768 Connector Pin 1 Pin 1 Pack 1 C771 Connector Pin 1 Pin 1 The mea...

Page 93: ...ontinuity between the following points on the HV wiring Continuity Resistance is less than or equal to 2ohms S Box C772P Connector Pin 1 Pin 1 Pack 1 C771P Connector Pin 1 Pin 1 Pack 1 C768P Connector...

Page 94: ...ecialized troubleshooting If this error is raised the BMS will request the vehicle to shut down and charging will be terminated immediately The vehicle will not be able to restart until the error is r...

Page 95: ...ed Fault reason 38 is raised by the BMS when the voltage ramp up exceeds the required time limit a short circuit or overcurrent is detected in the precharge circuit or the BMS fails to complete its in...

Page 96: ...Solutions BMS has detected an ESS internal failure which requires support from Dana 1 ESS internal failure 1 Contact Dana If this error is raised the vehicle will not be able to start HMI displays or...

Page 97: ...vehicle to shut down In all cases the vehicle will not be able to restart until the error is cleared Fault reason 43 indicates that the error occurred while in charging mode In this case the isolation...

Page 98: ...a for further investigation No Yes Has this error occurred while charging the vehicle Unplug EVSE and turn Key OFF for 1 hour Always report any instance of these faults to DANA Turn on ignition Has th...

Page 99: ...le will only be able to drive in limp mode and regenerative braking will be disabled HMI displays or logs Fault code F0026 and BMS fault reason 44 Refer to the CAN investigation subtree Investigate CA...

Page 100: ...rom Dana 1 ESS internal failure 1 Contact Dana If this error is raised the vehicle will only be able to drive in limp mode and regenerative braking will be disabled Charging will be terminated The veh...

Page 101: ...ible Solutions BMS has detected an ESS internal failure which requires support from Dana 1 ESS internal failure 1 Contact Dana If this error is raised charging will be terminated HMI displays or logs...

Page 102: ...Box 2 Loss of continuity due to defective HV connector or MSD 1 Connect MSD or HV connector 2 Replace HV harness or MSD If this error is raised the vehicle will only be able to drive in limp mode and...

Page 103: ...or equal to 2ohms MSD MSD Connector pin Connector pin HV 1 HV 2 LV 1 LV 2 Continued on next page WARNING Electrical hazard Follow Safety Warnings and High Voltage Shutdown Procedures defined in the S...

Page 104: ...Defective MSD Replace MSD Inform DANA before restarting the truck Disconnect connectors C718 C719 C716 and C717 from the S Box Refer to connector investigation subtree Was a defect found in the high...

Page 105: ...is separate from the main vehicle HVIL The S Box HVIL is a low voltage circuit passing through each HV connector on the S Box If any of these connectors is unplugged the HVIL will be broken and the B...

Page 106: ...17 from the S Box Refer to connector investigation subtree Was a defect found in the high voltage connectors No Yes Contact Dana for further investigation Defective harness Replace harness WARNING Ele...

Page 107: ...ult reason 50 52 54 56 58 60 62 64 66 68 or 70 is raised the vehicle will only be able to drive in limp mode and regenerative braking power will be limited to 25 If any of fault reasons 50 through 70...

Page 108: ...utions BMS has detected an ESS internal failure which requires support from Dana 1 ESS internal failure 1 Contact Dana If this error is raised during charging charging will be terminated HMI displays...

Page 109: ...s when the vehicle is connected to a level 2 charger it is likely that the original charger was inadequate or defective HMI displays or logs Fault code F0026 and BMS fault reason 73 Unplug the EVSE fr...

Page 110: ...charger If the error disappears when the vehicle is connected to a level 2 charger the original charger maybe defective HMI displays or logs Fault code F0026 and BMS fault reason 74 Unplug the EVSE f...

Page 111: ...If they appear please contact Dana for further investigation 1 S Box internal failure or software error 1 Contact Dana If fault reason 75 or 77 is raised charging will be terminated If fault reason 76...

Page 112: ...ption Possible Causes Possible Solutions BMS has detected an ESS internal failure which requires support from Dana 1 ESS internal failure 1 Contact Dana HMI displays or logs Fault code F0026 and BMS f...

Page 113: ...Reason 4 5 6 error Note If requested during this procedure to connect the vehicle to a charger a level 2 charger is required Note Make sure HV systems are not in use while charging Note For best ESS p...

Page 114: ...e error message still displayed on the HMI No Yes Complete Plug in only a level 2 AC charger Charge vehicle until charge cycle automatically ends Does the HMI also display F0026 BMS 1 2 3 4 5 6 No Yes...

Page 115: ...lure which requires support from Dana 1 ESS internal failure 1 Contact Dana If fault reason 102 is raised regenerative braking power will be limited to 50 If fault reason 103 or 104 is raised regenera...

Page 116: ...lt reason code indicating the specific reason the limitation was requested The BMS will request driving to be disabled in response to fault reason 5 6 7 12 13 15 16 29 37 41 or 42 If error F0027 appea...

Page 117: ...indicating the specific reason the limitation was requested The BMS will request the high voltage power to be limited to 50 in response to fault reason 4 11 14 22 23 24 32 33 34 or 40 If error F0028 a...

Page 118: ...fault reason code indicating the specific reason the limitation was requested The BMS will request the vehicle to shut down in response to fault reason 6 7 13 29 37 or 42 If error F0029 appears witho...

Page 119: ...0026 which provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will request the vehicle to shut down in response to fault reason 16 If error F0030 appe...

Page 120: ...reason the limitation was requested The BMS will request regenerative braking to be disabled in response to fault reason 1 2 3 7 9 10 15 16 26 27 28 29 37 41 42 44 45 47 48 103 or 104 If error F0032...

Page 121: ...n code indicating the specific reason the limitation was requested The BMS will request the regenerative braking power to be limited to 25 in response to fault reason 52 54 56 58 60 62 64 66 68 or 70...

Page 122: ...BMS fault reason code indicating the specific reason the limitation was requested The BMS will request the regenerative braking power to be limited to 50 in response to fault reason 8 14 25 40 or 102...

Page 123: ...de The BMS independently monitors isolation resistance and will raise error F0026 BMS fault reason 40 41 42 or 43 if there is a HV system isolation fault condition detected VCU and BMS fault code may...

Page 124: ...de The BMS independently monitors isolation resistance and will raise error F0026 BMS fault reason 40 41 42 or 43 if there is a HV system isolation fault condition detected VCU and BMS fault code may...

Page 125: ...The BMS independently monitors isolation resistance and will raise error F0026 BMS fault reason 40 41 42 or 43 if there is a HV system isolation fault condition detected VCU and BMS fault code may bot...

Page 126: ...istance and will raise error F0026 BMS fault reason 40 41 42 or 43 if there is a HV system isolation fault condition detected VCU and BMS fault code may both appear for the same problem Warning Loss o...

Page 127: ...ndicating a specific problem with the ESS cooling system The technician should troubleshoot the specific error HMI displays or logs Fault code F0039 No Yes Is F0019 F0020 or F0045 also present Refer t...

Page 128: ...error F0026 which provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will limit the charging rate in response to fault reason 47 If error F0040 appear...

Page 129: ...provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will terminate the charging process and open the charging relay in response to fault reason 7 or 3...

Page 130: ...The BMS will terminate the charging process in response to fault reason 1 2 3 8 9 10 15 16 28 29 43 45 46 48 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 73 74 75 or 77 If error F0042 appears wi...

Page 131: ...or F0026 which provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will prohibit the vehicle from starting in response to fault reason 28 29 37 38 39 4...

Page 132: ...rt again after shutdown This error is expected to be accompanied by error F0026 which provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will prohibit...

Page 133: ...tion was requested The BMS will request the ESS cooling system to shut off in response to fault reason 35 If error F0045 appears without one of the listed F0026 BMS fault reasons the technician should...

Page 134: ...le flow reduction Is there any evidence of a defect causing a cooling reduction Yes No Repair the defect as per the maintenance manual instructions Is there any evidence of a defect causing a cooling...

Page 135: ...ich provides a BMS fault reason code indicating the specific reason the limitation was requested The BMS will request the ESS heating circuit to shut off in response to fault reason 36 49 or 50 If err...

Page 136: ...CU has detected that the maximum cell voltage in the ESS is above a critical threshold The vehicle is requested to shut down This error is expected to be accompanied by error F0026 BMS fault reason 1...

Page 137: ...has detected that the maximum cell temperature in the ESS is above a critical threshold The vehicle is requested to shut down This error is expected to be accompanied by error F0026 BMS fault reason 1...

Page 138: ...CU has detected that the minimum cell voltage in the ESS is below a critical threshold The vehicle is requested to shut down This error is expected to be accompanied by error F0026 BMS fault reason 4...

Page 139: ...ic error F0026 BMS fault reason 35 should also be raised If not the technician should contact Dana for further investigation Troubleshooting for this error is the same as for F0026 BMS fault reason 35...

Page 140: ...evel in the ESS cooling system 1 Leak in ESS cooling system 2 Loss of continuity between chiller and coolant level sensor due to defective LV connector or harness 3 Defective coolant level sensor 1 Re...

Page 141: ...o Yes Replace the cooling tank following the maintenance manual instructions Replace the faulty cooling pipes following the maintenance manual instructions Turn ignition OFF Is the chiller tank liquid...

Page 142: ...2ohms C40 Tank C39 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 C40 Chiller C46 Connector pin Connector pin Pin 35 Pin 1 Pin 36 Pin 2 Is there any evidence of a continuity loss Yes No Defecti...

Page 143: ...ESS battery packs 1 ESS fault 1 Troubleshoot specific error This error is expected to be accompanied by F0026 BMS fault reason 30 If not the technician should contact Dana for further investigation E...

Page 144: ...he fault code still present No Yes Complete Plug in only a level 2 AC charger Charge vehicle until charge cycle automatically ends Is F0026 BMS 1 2 3 4 5 6 also present No Yes Refer to the specific er...

Page 145: ...connector or harness 3 Battery TMS internal failure 1 Plug in HV connector 2 Replace HV harness 3 Replace Battery TMS The purpose of the HVIL is to provide a warning if any HV connector is unplugged...

Page 146: ...Connector pin Connector pin Pin 3 Pin 4 Is there any evidence of a continuity loss No Yes Defective harness Replace harness Contact Dana for further investigation Is F0019 or F0020 also present No Ye...

Page 147: ...s required Note For best ESS performance and vehicle range HV batteries must regularly be changed to 100 SOC Vehicle SOC is a calculated valued that drifts over time It is recalibrated only at the end...

Page 148: ...uring this procedure to connect the vehicle to a charger a level 2 charger is required Note For best ESS performance and vehicle range HV batteries must regularly be changed to 100 SOC Vehicle SOC is...

Page 149: ...quested during this procedure to connect the vehicle to a charger a level 2 charger is required Note For best ESS performance and vehicle range HV batteries must regularly be changed to 100 SOC Vehicl...

Page 150: ...p wiring 6 CAN communication problem 7 Loss of power to MPDM or MPDM internal failure 8 VCU internal failure 1 Replace defective fuse or relay 2 Replace 12V fuse F19 3 Replace defective relay 4 Replac...

Page 151: ...151 Troubleshooting Connector C44 Connector C50 Connector C53 Connector C54 Connector C75 Connector C76...

Page 152: ...152 Troubleshooting Connector C93P pin Connector C93S socket Connector C100 Connector C367P pin Connector C367S socket...

Page 153: ...N investigation subtree Investigate CAN A and CAN C network Take the actions prescribed in the subtree Is the error code still displayed Yes No Complete Does the HMI also display MPDM No contact No Ye...

Page 154: ...I also display F0080 No Does the HMI also display F0084 Yes Yes Yes Yes Refer to error F0064 troubleshooting tree Refer to error F0069 troubleshooting tree Refer to error F0071 troubleshooting tree Re...

Page 155: ...9 in order to take continuity measures from inside the fuse box Is fuse F19 blown or intermittent No Yes Refer to connector investigation subtree Continued from previous page A Continued on next page...

Page 156: ...C93S C76 Connector pin Connector pin Pin 5 Pin 1 Pin 8 Pin 4 Pin 6 Pin 4 C93P C40S Connector pin Connector pin Pin 8 Pin 11 Pin 6 Pin 9 C40P C367S Connector pin Connector pin Pin 11 Pin 8 Pin 9 Pin 11...

Page 157: ...Pin 7 C40S C100 Connector pin Connector pin Pin 2 Pin 30 C76 C40S Connector pin Connector pin Pin 2 Pin 31 C76 C40S Connector pin Connector pin Pin 30 Pin N C40P C50S Connector pin Connector pin Pin 3...

Page 158: ...f the relay No Yes Defective relay Replace relay Is the error still occurring on further key ON or charge cycles No Yes Contact Dana for further investigation Complete Defective supervisory controller...

Page 159: ...to relay investigation subtree Investigate relay K004 K005 K007 K006 Turn ignition OFF and disconnect F19 from 12V fuse box C14 WARNING Electrical hazard Follow Safety Warnings and High Voltage Shutd...

Page 160: ...s and wires between the two test points of the harness ends C9 GND strip1 12V fuse box C14 C9 Ground Terminal Is there any evidence of a short circuit within the harness Yes No Defective harness Repla...

Page 161: ...the CAN B network Charge controller The charge controller manages the charging process It is powered by 12V low voltage from the MPDM and communicates via the CAN A network Charge Inlet The charge in...

Page 162: ...ler F0005 F0006 or F0007 OBC F0088 or ESS F0026 Other VCU errors related to charging F0004 or F0131 may also appear HMI displays or logs Fault code F0003 Does the HMI also display F0004 F0005 F0006 F0...

Page 163: ...n system reaches 95 of the ESS voltage The vehicle is then enabled to start If the HV distribution system fails to reach the required threshold within 5 seconds the VCU will flag precharge as failed a...

Page 164: ...tive EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE This error is expected to be accompanied by error F0042 If this is the case the technician should troubleshoot error F0042...

Page 165: ...ge Yes Refer to the F0042 troubleshooting tree Contact Dana for further investigation Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Re...

Page 166: ...Solutions VCU has detected a loss of communication with the BMS during charging 1 No contact with BMS 2 Incompatible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EV...

Page 167: ...Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No...

Page 168: ...estart charge with compatible EVSE This message is not displayed to the driver but may still appear in the HMI fault log If charge controller Charge end reason 3 appears without any other errors and t...

Page 169: ...n Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No No Has error F0026 F0154 or F0155 been raised previously du...

Page 170: ...tible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by a BMS error F0026 that triggered the fault If F0026 is not raised...

Page 171: ...pplicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Com...

Page 172: ...fline during charging 1 Various faults 2 Incompatible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE If no other error has been raised it may be possible to reso...

Page 173: ...f applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes...

Page 174: ...e When requested to connect the vehicle to an EVSE either a level 2 or level 3 EVSE can be used Yes Is the vehicle able to charge completely to 100 without raising the same fault Yes Contact Dana for...

Page 175: ...patible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by one or more ESS errors F0026 F0047 or F0049 that triggered the...

Page 176: ...if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Ye...

Page 177: ...ctive EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by one or more ESS errors F0026 or F0048 that triggered the fault If no BMS error...

Page 178: ...cable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complet...

Page 179: ...lt 2 Incompatible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by one or more of F0026 and F0092 If neither of these er...

Page 180: ...cable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complet...

Page 181: ...compatible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by one or more Supervisory controller error messages F0051 or F...

Page 182: ...ble Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete...

Page 183: ...if any HV connector is unplugged without the HV distribution being safely ended The charge controller will raise this fault code if any HVIL error occurs during charging This error is expected to be...

Page 184: ...plug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the...

Page 185: ...roller has detected that the EVSE went offline during charging 1 EVSE lost power during charging 2 Incompatible or defective EVSE 1 No action needed this is the intended vehicle function 2 Restart cha...

Page 186: ...omplete Investigate the shop power for operation interruptions during charge Could you find any defect with shop power supply Yes No Complete Contact Dana for further investigation HMI displays or log...

Page 187: ...vehicle is moving it will occur as soon as the vehicle speed drops below 5 km h The VCU will notify the driver immediately by raising error F0058 and will prohibit restarting the vehicle If the cut lo...

Page 188: ...applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes C...

Page 189: ...2 Incompatible or defective EVSE 1 Troubleshoot specific error 2 Restart charge with compatible EVSE The error is expected to be accompanied by the VCU error F0095 that triggered the fault If F0095 i...

Page 190: ...it for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No HMI...

Page 191: ...nector or harness 1 Reconnect EVSE if further charging is needed 2 Restart charge with compatible EVSE 3 Replace LV connector or harness per Service Manual Warning High voltage hazard The harness betw...

Page 192: ...to charge completely to 100 without sending any fault Yes Complete If this is the first time you are restarting charge try to use the same EVSE if the errors comes up repeatedly then try to restart t...

Page 193: ...inlet Connector pin Connector pin Pin E1 Pin 2 Pin F1 Pin 1 Is there any evidence of a continuity loss in the harness Yes No Defective harness Replace harness WARNING Electrical hazard Follow Safety W...

Page 194: ...is not displayed to the driver but may still appear in the HMI fault log If charge controller Charge end reason 16 appears without any other errors and the SOC is at 100 then the charging system is o...

Page 195: ...a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No No Has error F0153 F0154 or F0155 been raised previously during or bef...

Page 196: ...compatible EVSE The purpose of the HVIL is to provide a warning if any HV connector is unplugged without the HV distribution being safely ended The charge controller will raise this fault code if an H...

Page 197: ...unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge HMI displays or logs Fault code F0005 and Charge end reason 17 Fau...

Page 198: ...vehicle able to charge completely to 100 without raising the same fault Yes Complete No Has error F0061 F0062 F0088 0x3302 been raised previously during or before this charge No Yes Refer to the corr...

Page 199: ...e EVSE 1 Troubleshoot specific error 2 Troubleshoot specific error 3 Restart charge with compatible EVSE The error is expected to be accompanied by the OBC error F0088 that triggered the fault If erro...

Page 200: ...unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge HMI displays or logs Fault code F0005 and Charge end reason 18 Fau...

Page 201: ...201 Troubleshooting Contact Dana for further investigation Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No Continued from previous page...

Page 202: ...ntact with OBC 1 Troubleshoot specific error 2 Troubleshoot specific error The error is expected to be accompanied by the OBC error F0088 that triggered the fault If error F0088 is not raised it may b...

Page 203: ...unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge HMI displays or logs Fault code F0005 and Charge end reason 19 Fau...

Page 204: ...204 Troubleshooting Contact Dana for further investigation Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No Continued from previous page...

Page 205: ...tion error with OBC 1 Troubleshoot specific error 2 Troubleshoot specific error The error is expected to be accompanied by the OBC error F0088 that triggered the fault If error F0088 is not raised it...

Page 206: ...unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge HMI displays or logs Fault code F0005 and Charge end reason 20 Fau...

Page 207: ...207 Troubleshooting Contact Dana for further investigation Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No Continued from previous page...

Page 208: ...raise their own errors F0026 and F0153 respectively if an imbalance is detected If charge controller fault reason 21 appears without either of these errors it may be possible to resolve the error by...

Page 209: ...e F0007 and Charge end reason 21 Unplug charger and put the vehicle in accessory mode Access the fault log on the HMI Drive the truck for a few minutes in order to discharge the High Voltage battery a...

Page 210: ...leshooting tree Contact Dana for further investigation Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to st...

Page 211: ...unction This message is not displayed to the driver but may still appear in the HMI fault log If charge controller fault reason 22 appears without any other errors and the SOC is at 100 then the charg...

Page 212: ...nd Charge end reason 22 Fault code F0006 and Charge end reason 22 Fault code F0007 and Charge end reason 22 Contact Dana for further investigation Turn ignition OFF and unplug the EVSE if applicable W...

Page 213: ...utions Battery pack being discharged during charge 1 Excessive use of accessories while charging 2 Incompatible or defective EVSE 1 Shut off accessories while charging 2 Restart charge with compatible...

Page 214: ...nd reason 23 Fault code F0006 and Charge end reason 23 Fault code F0007 and Charge end reason 23 Contact Dana for further investigation Turn the vehicle OFF and unplug the EVSE if applicable Wait for...

Page 215: ...SS fault 2 EVSE error 1 Troubleshoot specific error 2 Restart charge session This error is expected to be accompanied by error F0041 If this is the case the technician should troubleshoot error F0041...

Page 216: ...it for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No HMI...

Page 217: ...starting and has requested the vehicle to shut down If the vehicle does not shut down within 35 seconds relays will be opened to immediately isolate the ESS The vehicle will not be able to start agai...

Page 218: ...it for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes Complete No HMI...

Page 219: ...ific error 2 Restart charge with compatible EVSE This error is expected to be accompanied by one or more of errors F0026 F0041 or F0042 If this is the case the technician should troubleshoot the speci...

Page 220: ...applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes C...

Page 221: ...pecific error 2 Restart charge session This error is expected to be accompanied by one or more of errors F0026 F0047 F0153 or F0154 If this is the case the technician should troubleshoot the specific...

Page 222: ...if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100 without raising the same fault Yes...

Page 223: ...be possible to resolve the error by restarting the charge using a compatible EVSE If not please contact Dana for further troubleshooting Note When requested to connect the vehicle to an EVSE either a...

Page 224: ...rt charge session This message is not displayed to the driver but may still appear in the HMI fault log If charge controller fault reason 29 appears without any other errors and the SOC is at 100 or o...

Page 225: ...e F0006 and Charge end reason 29 Fault code F0007 and Charge end reason 29 Has the message been raised after the vehicle has been charged and the SOC has reached 100 on both High Voltage batteries No...

Page 226: ...rt charge session This message is not displayed to the driver but may still appear in the HMI fault log If charge controller fault reason 30 appears without any other errors and the SOC is at 100 or o...

Page 227: ...e F0006 and Charge end reason 30 Fault code F0007 and Charge end reason 30 Has the message been raised after the vehicle has been charged and the SOC has reached 100 on both High Voltage batteries No...

Page 228: ...rt charge session This message is not displayed to the driver but may still appear in the HMI fault log If charge controller fault reason 31 appears without any other errors and the SOC is at 100 or o...

Page 229: ...F0006 and Charge end reason 31 Fault code F0007 and Charge end reason 31 Has the message been raised after the vehicle has been charged and the SOC has reached 100 on both High Voltage batteries No Y...

Page 230: ...is at 100 or other operator defined maximum then the charging system is operating correctly and no troubleshooting is needed Otherwise it may be possible to resolve the error by restarting the charge...

Page 231: ...F0006 and Charge end reason 32 Fault code F0007 and Charge end reason 32 Has the message been raised after the vehicle has been charged and the SOC has reached 100 on both High Voltage batteries No Y...

Page 232: ...tion Possible Causes Possible Solutions VCU has reported a timeout of the charge controller during charging 1 No contact with charge controller 1 Troubleshoot specific error Note When requested to con...

Page 233: ...estigation Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge com...

Page 234: ...or Description Possible Causes Possible Solutions VCU has reported a loss of contact with the OBC 1 OBC fault or no contact with OBC 1 Troubleshoot specific error Note When requested to connect the ve...

Page 235: ...Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to...

Page 236: ...charge session This fault code is a status message indicating that the VCU has determined that charging is completed If the charge controller does not terminate the charge within 5 seconds the VCU wil...

Page 237: ...Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to...

Page 238: ...system 1 ESS fault 2 EVSE error 1 Troubleshoot specific error 2 Restart charge session The error is expected to be accompanied by one or more of F0026 and F0027 If neither of these errors is raised i...

Page 239: ...n ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge completely to 100...

Page 240: ...0x3456 TT1 0x4010 TT1 0x4609 TT1 0x0008 TT1 0x1803 TT1 0x3457 TT1 0x4011 TT1 0x460A TT1 0x0009 TT1 0x1850 TT1 0x3458 TT1 0x4012 TT1 0x460B TT1 0x000A TT1 0x1851 TT1 0x3459 TT1 0x4013 TT1 0x460C TT1 0...

Page 241: ...TT1 0x3405 TT1 0x3725 TT2 0x4201 TT1 0x5507 TT3 0x1602 TT1 0x3406 TT1 0x3726 TT1 0x4202 TT1 0x5508 TT1 0x1603 TT1 0x3407 TT1 0x3727 TT2 0x4203 TT1 0x5509 TT1 0x1604 TT1 0x3408 TT2 0x3728 TT2 0x4204 T...

Page 242: ...3 0x3450 0x3451 0x3452 0x3453 0x3454 0x3455 0x3456 0x3457 0x3458 0x3459 0x345A 0x345B 0x345C 0x345D 0x345E 0x345F 0x3460 0x3500 0x3501 0x3502 0x3503 0x3504 0x3507 0x3508 0x3509 0x350A 0x350B 0x350C 0x...

Page 243: ...s 5 CAN communication problem 6 OBC internal error 1 Update OBC software 2 Troubleshoot specific error 3 Restart charge with compatible EVSE 4 Replace LV connector or harness per Service Manual 5 Reso...

Page 244: ...244 Troubleshooting Connector C706 Connector C726 Connector C727 Connector C731 3 4 HVIL 2 HVIL 1...

Page 245: ...ifferent level 2 EVSE No Is the error still being raised on the HMI Yes Complete Does the HMI also display F0006 or F0007 Yes Refer to the corresponding error troubleshooting tree Update the OBC softw...

Page 246: ...onnector Pin 23 Pin H MPDM C12 Connector OBC C22 Connector Pin 22 Pin 1 Ground C100 Connector OBC C731P Connector Pin 1 Pin 1 HV JB C706P Connector OBC C731P Connector Pin 2 Pin 2 HV JB C706P Connecto...

Page 247: ...d or dirty No Yes Defective connection point Repair or replace appropriately Defective OBC Replace OBC Were you able to find a problem in the CAN B network Yes No Refer to CAN investigation subtree In...

Page 248: ...AN communication problem 6 OBC internal error 1 Update OBC software 2 Troubleshoot specific error 3 Replace HV fuse F2 4 Replace HV harness 5 Resolve CAN communication problem 6 Replace OBC Note This...

Page 249: ...249 Troubleshooting Connector C716 black Connector C717 green Connector C718 yellow Connector C719 orange Connector C731...

Page 250: ...n box Disconnect connector C731 from OBC Disconnect connector C718 C719 C716 and C717 from S box Refer to connector investigation subtree Update the OBC software version following the STT01 tree provi...

Page 251: ...C702P Connector S Box C716P Connector Pin 1 Pin 1 HV JB C701P Connector Pin 1 Pin 2 S Box C717P Connector HV JB C701P Connector RT056 RT057 RT056 Connector RT057 Connector RT056 RT057 RT052 Connector...

Page 252: ...2 blown or intermittent No Yes Replace fuse and inform DANA before taking further actions No Is the error still occurring on further key ON or charge cycles Yes Complete Contact Dana for further inves...

Page 253: ...Powertrain Coolant Pump fault 3 Cooling system problem 4 OBC internal error 1 Update OBC software 2 Troubleshoot specific error 3 Resolve cooling system problem 4 Replace OBC Note This troubleshooting...

Page 254: ...cooling system investigation subtree Could you find any defect that would cause the OBC to overheat No Yes Repair or replace any piece as per the cooling circuit investigation subtree instructions De...

Page 255: ...software update needed 2 CAN communication problem 3 OBC internal error 1 Update OBC software 2 Resolve CAN communication problem 3 Replace OBC Note This troubleshooting tree covers the following OBC...

Page 256: ...problem in the CAN B network Yes No Refer to CAN investigation subtree Investigate CAN B network Repair according to the actions prescribed in the subtree Is the error code still displayed Yes No Comp...

Page 257: ...C 0x1300 0x1400 0x3300 0x3304 0x3751 0x4009 0x4109 0x4205 0x4206 0x4605 0x4606 0x5300 0x5304 0x5652 and 0x5653 These errors indicate that the OBC has raised an internal status message which does not r...

Page 258: ...nitors continuity between the HVIL pins on its HV connectors C727 and C731 If this connector is unplugged unsafely the HVIL will be broken and the OBC will send an error message via CAN If one of the...

Page 259: ...wing points Continuity Resistance is less than or equal to 2ohms OBC C731P Connector Pin HVIL_A Pin HVIL_B OBC C731P Connector OBC C727S Connector Pin HVIL1 Pin HVIL2 OBC C727S Connector Is there any...

Page 260: ...ted that the high voltage batteries are being discharged during charging 1 Excessive use of accessories while charging 2 Incompatible or defective EVSE 3 ESS fault 1 Shut off accessories while chargin...

Page 261: ...investigation Turn ignition OFF and unplug the EVSE if applicable Wait for vehicle shutdown and wait 2 minutes after shutdown Reconnect a compatible EVSE to start charge Is the vehicle able to charge...

Page 262: ...ilure 1 Troubleshoot specific error 2 Replace LV connector or harness per Service Manual 3 Resolve CAN communication problem 4 Replace charge controller No Contact fault messages appear on the HMI dis...

Page 263: ...263 Troubleshooting Connector C53 Connector C100...

Page 264: ...check for continuity between the following points Continuity Resistance is less than or equal to 2ohms CCU C52 Connector C50P Connector Pin G4 Pin B CCU C52 Connector Pin H4 Pin C C50P Connector CCU...

Page 265: ...igation subtree Investigate CAN B network Repair according to the actions prescribed in the subtree Is the error code still displayed Yes No Complete With a multimeter check for continuity between the...

Page 266: ...nector or harness 3 CAN communication problem 4 OBC internal failure 1 Troubleshoot specific error 2 Replace LV connector or harness per Service Manual 3 Resolve CAN communication problem 4 Replace OB...

Page 267: ...e actions prescribed in the subtree Is the error code still displayed Yes No Complete No Disconnect connector C22 from OBC Does the HMI also display F0070 F0075 or F0082 Does the HMI also display MPDM...

Page 268: ...s Refer to the specific troubleshooting tree Disconnect connector C11 and C12 from MPDM Disconnect connector C100 from ground Refer to connector investigation subtree Turn ignition OFF Defective OBC R...

Page 269: ...r OBC 22 Connector Pin 22 Pin 1 Ground C100 Connector Is there any evidence of a continuity loss or a degraded connection No Yes Defective harness Replace harness Contact Dana for further investigatio...

Page 270: ...t is powered by AC high voltage supplied by the traction inverter Traction Inverter The traction inverter is the inverter and control unit which supplies and controls the motor The control stage is po...

Page 271: ...eed or on a steep slope or if regenerative braking is not possible because the high voltage batteries are near 100 state of charge SOC In these cases the vehicle is functioning normally and no trouble...

Page 272: ...ntact Dana for further investigation Were you able to find a defect in the CAN B or A network causing this error to be raised Yes No Repair as per the subtree instructions Refer to the CAN investigati...

Page 273: ...r internal failure 1 Troubleshoot specific error 2 Update traction inverter software and calibration 3 Replace traction inverter This error could also be raised if there is a problem with the high vol...

Page 274: ...274 Troubleshooting Connector C717 green Connector C718 yellow Connector C719 orange...

Page 275: ...ion inverter to the latest software and calibration following the instructions in the TM4 installation manual Yes Is the problem persisting on further drive cycles No Yes Complete WARNING Electrical h...

Page 276: ...With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms HV JB C702P S Box C718P Connector pin Connector pin Pin 1 Pin 1 HV JB C702P S...

Page 277: ...e LV connector or harness 4 Traction inverter internal failure 5 Motor internal failure 1 No action needed 2 Update traction inverter software and calibration 3 Replace LV connector or harness per Ser...

Page 278: ...ault reason 3 Flash the traction inverter to the latest software and calibration following the instructions in the TM4 installation manual Is the problem persisting on further drive cycles in similar...

Page 279: ...rt or a conductivity problem on the speed sensor cables No Yes Defective harness Replace harness Refer to connector investigation subtree Inspect the traction inverter connectors No Yes Defective trac...

Page 280: ...Park vehicle outdoors out of the sun and allow it to cool down for 2 hours 2 Troubleshoot specific error 3 Resolve cooling system problem 4 Replace traction inverter This error can occur if the ambie...

Page 281: ...0097 and Fault reason 4 Fault code F0098 and Fault reason 4 Yes No Yes No Complete Did the fault clear during normal operation Did the error occur under extreme conditions Max speed Max torque steep u...

Page 282: ...roubleshooting tree No Is the VCU displaying Radiator Fan 01 No Contact or Radiator Fan 02 No Contact Yes Refer to the specific error troubleshooting tree No Refer to the cooling system investigation...

Page 283: ...e and calibration 2 Replace traction inverter Propulsion System faults may also be investigated and resolved using the ODIN tool and the TM4 SUMO Powertrain Troubleshooting Guide Defective traction in...

Page 284: ...tion inverter software or calibration error 3 Traction inverter internal failure 1 No action needed 2 Update traction inverter software and calibration 3 Replace traction inverter This error can occur...

Page 285: ...TM4 installation manual Is the problem persisting on further drive cycles in similar conditions No Yes Complete HMI displays or logs Fault code F0097 and Fault reason 6 Fault code F0098 and Fault rea...

Page 286: ...r to traction inverter troubleshooting guide 4 Update traction inverter software and calibration In the event of an actual problem with the HV network error F0026 and or other errors raised by devices...

Page 287: ...287 Troubleshooting Connector C716 black Connector C717 green Connector C718 yellow Connector C719 orange...

Page 288: ...g an error Contact Dana for further investigation Does the HMI also display F0026 No Yes Refer to the F0026 troubleshooting tree No Flash the traction inverter to the latest software and calibration f...

Page 289: ...gh Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide A With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2...

Page 290: ...erter 1 Adverse driving conditions 2 Cooling fault 3 Cooling system problem 4 Traction inverter internal failure 1 Park vehicle outdoors out of the sun and allow it to cool down for 2 hours 2 Troubles...

Page 291: ...0097 and Fault reason 8 Fault code F0098 and Fault reason 8 Yes No Yes No Complete Did the fault clear during normal operation Did the error occur under extreme conditions Max speed Max torque steep u...

Page 292: ...roubleshooting tree No Is the VCU displaying Radiator Fan 01 No Contact or Radiator Fan 02 No Contact Yes Refer to the specific error troubleshooting tree No Refer to the cooling system investigation...

Page 293: ...due to overheating in the motor 1 Adverse driving conditions 2 Cooling fault 3 Cooling system problem 1 Park vehicle outdoors out of the sun and allow it to cool down for 2 hours 2 Troubleshoot specif...

Page 294: ...0097 and Fault reason 9 Fault code F0098 and Fault reason 9 Yes No Yes No Complete Did the fault clear during normal operation Did the error occur under extreme conditions Max speed Max torque steep u...

Page 295: ...ooting tree No Is the VCU displaying Radiator Fan 01 No Contact or Radiator Fan 02 No Contact Yes Refer to the specific error troubleshooting tree No Refer to the cooling system investigation subtree...

Page 296: ...or traction F0098 due to an internal failure of the motor 1 Motor internal failure 1 Replace motor Propulsion System faults may also be investigated and resolved using the ODIN tool and the TM4 SUMO...

Page 297: ...overcurrent in the high voltage batteries 1 Adverse driving conditions 2 Traction inverter software or calibration error 1 Park vehicle outdoors out of the sun and allow it to cool down for 2 hours 2...

Page 298: ...torque steep uphill downhill extremely hot temperature Let the truck cool down for 2 hours parked outside not under the sun with the ignition switched OFF Does the fault occur again during a test dri...

Page 299: ...harness 5 Defective relay K004 1 Replace MPDM fuse F5 2 Replace 12V fuse F19 3 Replace LV connector or harness per Service Manual 4 Replace LV connector or harness per Service Manual 5 Replace relay K...

Page 300: ...300 Troubleshooting Connector C40 Connector C50 Connector C53 Connector C676 Connector C93P pin Connector C93S socket Connector C91...

Page 301: ...ector C4 from K004 Remove fuse F19 in order to take continuity measures from inside the fuse box Inspect fuse F5 and F4 on MPDM and fuse F19 on 12V fuse box C14 Is fuse F5 on MPDM blown or intermitten...

Page 302: ...er to the connector investigation subtree With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms 12V fuse box C14 K004 C4 Terminal Con...

Page 303: ...C676P C676P Connector pin Connector pin Pin 31 Pin 28 C91S C40S Connector pin Connector pin Pin 28 Pin L C40P C50S Connector pin Connector pin Pin L Pin K1 C50P C53 Connector pin Connector pin Continu...

Page 304: ...MPDM Restart the vehicle Complete Did fuse F5 blow again during test drive No Turn ignition OFF and disconnect F5 from MPDM A Continued on next page Is there any problem with the connector integrity...

Page 305: ...act Dana for further investigation Complete With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wir...

Page 306: ...on 12V fuse box C14 Restart the vehicle Complete Did fuse F19 blow again during test drive No Turn ignition OFF and disconnect F19 from 12V fuse box C14 B Continued on next page Is there any problem w...

Page 307: ...No Yes Contact Dana for further investigation Complete With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connect...

Page 308: ...MPDM Restart the vehicle Complete Did fuse F4 blow again during test drive No Turn ignition OFF and disconnect F4 from MPDM C Continued on next page Is there any problem with the connector integrity...

Page 309: ...following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends Pin B GND strip1 C11 MPDM Ground Connector pin...

Page 310: ...overed in traction inverter troubleshooting guide 1 Refer to traction inverter troubleshooting guide Propulsion System faults may also be investigated and resolved using the ODIN tool and the TM4 SUMO...

Page 311: ...er Service Manual 2 Replace motor 3 Replace traction inverter 4 Troubleshoot specific error The traction inverter has its own internal interlock system which detects if a connector on the motor or tra...

Page 312: ...connector from speed sensor Refer to the connector investigation subtree Does the HMI also display F0061 or F0062 No Yes Contact Dana for further investigation WARNING Electrical hazard Follow Safety...

Page 313: ...error message still appearing on the HMI Turn ignition ON Yes No Defective speed sensor Replace motor Reconnect the speed sensor connector to the motor speed sensor Turn ignition ON Is the error messa...

Page 314: ...harness Turn ignition OFF Place the jumper between pin J and K on connector C3 on the traction inverter Is the error message still appearing on the HMI Turn ignition ON Yes No Defective traction inver...

Page 315: ...eplace harness 3 Replace traction inverter The Traction inverter has its own internal interlock system which detects if a connector on the motor or traction inverter is unplugged If a discontinuity is...

Page 316: ...tor C3 to the traction inverter Turn ignition ON Yes No Complete Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the S...

Page 317: ...the ODIN tool and the TM4 SUMO Powertrain Troubleshooting Guide HMI displays or logs Fault code F0100 and Traction inverter fault reason 4 Check that the traction inverter cover is properly installed...

Page 318: ...inverter troubleshooting guide This is a warning message for the driver indicating that the normal level of regenerative braking is not available while cruise control is active The driver therefore ma...

Page 319: ...eached Maximum tree HMI displays or logs Fault code F0102 Was this error raised at high SOC on high voltage batteries No Yes Complete Was this error raised with cruise control active No Yes Contact Da...

Page 320: ...uced Error Description Possible Causes Possible Solutions Traction inverter software error which requires support from Dana 1 Traction inverter software error 1 Contact Dana Contact Dana for further i...

Page 321: ...Loss of continuity due to defective LV connector or harness 2 Accelerator pedal internal failure 1 Replace LV connector or harness per Service Manual 2 Replace accelerator pedal The accelerator pedal...

Page 322: ...322 Troubleshooting Connector C651 B Circuit73...

Page 323: ...ltimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms AccPedal C655 VCU 651 A Connector pin Connector pin Pin 4 Pin 51 Pin 2 Pin 9 Pin 3 Pin 2...

Page 324: ...inverter No Contact fault messages appear on the HMI display and remain while the fault is active Historical No Contact fault messages can be found in the HMI logs by selecting the MC43 2 log HMI dis...

Page 325: ...powered by high voltage while the control unit is powered by 24V DC low voltage and communicates via a CAN network iAPU The intelligent Air Processing Unit iAPU controls the air brake compressor to m...

Page 326: ...son 0x02faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0000 and Air Brake DTC 0...

Page 327: ...son 0x05faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0000 and Air Brake DTC 0...

Page 328: ...07faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Air Brake DTC 0x07faf...

Page 329: ...08faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Air Brake DTC 0x08faf...

Page 330: ...air dryer cartridge 2 Contact Dana HMI displays or logs Fault code F0000 and Air Brake DTC 0x0afaf0 0x0afae0 Turn ignition OFF Replace the cartridge as per the Bendix maintenance manual instructions...

Page 331: ...Error Description Possible Causes Possible Solutions Air brake compressor has reported a low oil level 1 Low oil level in air brake compressor 2 Air brake compressor internal failure 1 Repair any leak...

Page 332: ...leaks on and around the air brake compressor Contact Dana for further investigation Could you find any oil leak Yes No Repair the leak according to the Bendix maintenance manual instructions Refill th...

Page 333: ...from the iAPU 1 iAPU or air brake compressor fault 2 iAPU internal failure 1 Troubleshoot specific error 2 Contact Dana HMI displays or logs Fault code F0000 and Air Brake DTC 0x233608 0x233708 0x2338...

Page 334: ...cription Possible Causes Possible Solutions Air brake compressor has reported an internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Air B...

Page 335: ...cription Possible Causes Possible Solutions Air brake compressor has reported an internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Air B...

Page 336: ...scription Possible Causes Possible Solutions Air brake compressor has reported an internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Air...

Page 337: ...e Causes Possible Solutions iAPU has reported that the air brake compressor electric motor experienced an overload 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault cod...

Page 338: ...iption Possible Causes Possible Solutions iAPU has reported an air brake compressor internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0000 and Ai...

Page 339: ...Description Possible Causes Possible Solutions iAPU has reported a low oil level in the air brake compressor 1 Low oil level in air brake compressor 2 Air brake compressor internal failure 1 Repair an...

Page 340: ...eaks on and around the air brake compressor Contact Dana for further investigation Could you find any oil leaks Yes No Repair the leaks according to the Bendix maintenance manual instructions Refill t...

Page 341: ...1 Change oil in air brake compressor per manufacturer s instructions HMI displays or logs Fault code F0000 and Air Brake DTC 0xa4f8ff Change the air brake compressor oil according to Bendix procedure...

Page 342: ...Possible Causes Possible Solutions iAPU has reported that the air brake compressor electric motor and or circuitry are overheated 1 Problem with cooling system 2 Air brake compressor internal failure...

Page 343: ...ck if the error is being raised again Is the error eventually raised again Yes No Complete Refer to the cooling investigation subtree Were you able to find a defect within the cooling circuit Yes No D...

Page 344: ...Description Possible Causes Possible Solutions iAPU has reported that the air brake compressor mechanism is overheated 1 Problem with cooling system 2 Air brake compressor internal failure 1 Resolve...

Page 345: ...ck if the error is being raised again Is the error eventually raised again Yes No Complete Refer to the cooling investigation subtree Were you able to find a defect within the cooling circuit Yes No D...

Page 346: ...reported an error in CAN communication with the air brake compressor 1 Loss of contact with iAPU or air brake compressor 2 CAN communication problem 3 Air brake compressor internal failure 4 iAPU int...

Page 347: ...vestigate CAN A network Take the actions prescribed in the subtree Is the error code still displayed Yes No Complete Contact Dana for further investigation Does the HMI also display Air Dryer No conta...

Page 348: ...rror Description Possible Causes Possible Solutions iAPU has reported that one of the onboard pneumatic circuits has reached its maximum pressure level 1 Pressure temporarily high 2 iAPU internal fail...

Page 349: ...educe the air pressure in the air tanks below 9 bar Measure and observe the air tank pressures Put the truck in ready mode after reducing the pressure in the brake circuit Does the error code appear a...

Page 350: ...Description Possible Causes Possible Solutions iAPU has detected possible condensed water in the pneumatic system 1 Air dryer cartridge in need of replacement 2 iAPU internal failure 1 Drain excess wa...

Page 351: ...air any air leaks Drain water from the wet tank by the iAPU by opening the air tank purge valve at the bottom of the tank Replace iAPU dryer cartridge according to the Bendix maintenance manual instru...

Page 352: ...ason 0xd9f9e2 Error Description Possible Causes Possible Solutions iAPU has reported an improbably high pressure in one of the onboard pneumatic circuits 1 iAPU internal error 1 Follow trouble tree to...

Page 353: ...ension circuits Measure and observe the air tank pressures the service brake and the suspension circuits Fill air brake system until air brake compressor cut off pressure Does the error code appear ag...

Page 354: ...ason 0xdaf9e2 Error Description Possible Causes Possible Solutions iAPU has reported an improbably high pressure in one of the onboard pneumatic circuits 1 iAPU internal error 1 Follow trouble tree to...

Page 355: ...rvice brake and the suspension circuits Fill air brake system until air brake compressor cut off pressure Does the error code appear again No Yes Contact Dana for further investigation Complete Repeat...

Page 356: ...activated on the iAPU 1 Service mode active 1 Clear error using Bendix service tool HMI displays or logs Fault code F0000 and Air Brake DTC 0xfef9ff Contact Dana for further investigation Does error...

Page 357: ...dge is due for replacement 1 Air dryer cartridge in need of replacement 1 Replace air dryer cartridge HMI displays or logs Fault Code F0001 Replace air dryer filter Contact Dana for further investigat...

Page 358: ...son 0x00faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air Brake DTC 0...

Page 359: ...son 0x01faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air Brake DTC 0...

Page 360: ...son 0x03faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air Brake DTC 0...

Page 361: ...0x04f9e2 Error Description Possible Causes Possible Solutions iAPU CAN Bus off failure occurred 1 No contact with iAPU or air brake compressor 2 CAN communication problem 1 Troubleshoot specific erro...

Page 362: ...ing tree Does the HMI also display Brake Compressor No contact Yes Refer to the Brake Compressor No contact troubleshooting tree No Were you able to find a problem in the CAN A network Yes No Refer to...

Page 363: ...sure sensor failure 1 Air leak from port 41 on iAPU 2 iAPU internal failure 1 Correctly plug port 41 on iAPU 2 Replace iAPU HMI displays or logs Fault code F0002 and Air Brake DTC 0x04faff Defective i...

Page 364: ...son 0x06faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air Brake DTC 0...

Page 365: ...09faff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Contact Dana HMI displays or logs Fault code F0002 and Air Brake DTC 0x09faf...

Page 366: ...ble Solutions Air brake compressor has reported a critical undervoltage on its HV supply 1 ESS fault 2 Loss of continuity due to defective HV connector or harness 3 Blown HV fuse F4 1 Troubleshoot spe...

Page 367: ...nnector C795 from High Voltage junction box Disconnect connector C790 from air brake compressor Is there any problem with the connector integrity Refer to the connector investigation subtree Yes Defec...

Page 368: ...proper safety precautions open the HV junction box Inspect fuse F4 in the HV junction box Is fuse F4 blown or intermittent No Yes Continued from previous page Replace HV fuse and advise DANA that the...

Page 369: ...uses Possible Solutions Air brake compressor has reported a problem with the HV distribution system which requires support from Dana 1 HV distribution problem 1 Contact Dana HMI displays or logs Fault...

Page 370: ...rload condition 1 ESS fault 2 Air brake compressor internal failure 1 ESS fault 2 Air brake compressor internal failure HMI displays or logs Fault code F0002 and Air Brake DTC 0x232C01 Does the HMI al...

Page 371: ...cription Possible Causes Possible Solutions Air brake compressor has reported an internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0002 and Air B...

Page 372: ...233001 Error Description Possible Causes Possible Solutions Air brake compressor has reported that it is overheated 1 Problem with cooling system 2 Air brake compressor internal failure 1 Resolve cool...

Page 373: ...elow 85 C Turn ignition ON Is the error eventually raised again Yes No Complete Refer to the cooling investigation subtree Was a defect found in the cooling circuit Yes No Defective air brake compress...

Page 374: ...has reported an overcurrent condition on the analog high voltage interlock loop HVIL 1 Software or internal air brake compressor problem 1 Contact Dana Feature is not enabled Contact Dana if this fau...

Page 375: ...the HVIL is to provide a warning if any HV connector is unplugged without the HV distribution being safely ended The air brake compressor monitors continuity between the HVIL pins on its HV connector...

Page 376: ...na for further investigation Refer to the Analog HVIL investigation subtree Could you find any defect in the HVIL analog circuit Yes No Contact Dana for further investigation Repair as prescribed in t...

Page 377: ...onnector Replace harness Is there any evidence of continuity loss Yes Defective harness Replace harness No Contact Dana for further investigation Continued from previous page With a multimeter check f...

Page 378: ...cription Possible Causes Possible Solutions Air brake compressor has reported an internal failure 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0002 and Air b...

Page 379: ...son 0x3cf8e3 Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air brake DTC 0...

Page 380: ...son 0x3df8ff Error Description Possible Causes Possible Solutions iAPU has reported an internal failure 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air brake DTC 0...

Page 381: ...s out of range 1 DCDC or LV distribution fault 2 Blown 24V fuse F2 3 Loss of continuity due to defective LV connector or harness 4 iAPU internal failure 1 Troubleshoot specific error 2 Replace 24V fus...

Page 382: ...ing troubleshooting tree Is there any problem with the connector integrity Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Servi...

Page 383: ...ive iAPU Replace iAPU No Disconnect connector C40 and C367 Refer to the connector investigation subtree Turn ignition OFF Inspect fuse F2 on 24V fuse box C20 Is fuse F2 on 24V fuse box C20 blown or in...

Page 384: ...d Service Chart in the Service Manual No With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms C40S Connector pin Pin 2 A2 24V fuse b...

Page 385: ...en the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends 24V fuse box C20 Ground Terminal A2 Grou...

Page 386: ...iAPU has reported a dataset or software error 1 iAPU dataset or software error 1 Update dataset using Bendix service tool HMI displays or logs Fault code F0002 and Air brake DTC 0x75f7ed 0x74f7ec Usin...

Page 387: ...Solutions iAPU has reported input undervoltage or overvoltage at the air brake compressor 1 ESS fault 2 Loss of continuity due to defective HV connector or harness 3 Blown HV fuse F4 1 Troubleshoot s...

Page 388: ...nnect connector C795 from air brake compressor Disconnect connector C790 from HV junction box Refer to the connector investigation subtree Is there any problem with the connector integrity Yes Defecti...

Page 389: ...d advise DANA that the fuse was blown before restarting the truck WARNING Electrical hazard The High Voltage junction box cover and all HV connections must be reinstalled properly after replacing the...

Page 390: ...on Possible Causes Possible Solutions iAPU has reported an internal failure in the air brake compressor 1 Air brake compressor internal failure 1 Contact Dana HMI displays or logs Fault code F0002 and...

Page 391: ...MI displays or logs Fault code F0002 and Air brake DTC 0xa5f8e0 Turn ignition OFF and wait until compressor temperature is below 85 C Perform a test drive to check if the error is being raised again I...

Page 392: ...or logs Fault code F0002 and Air brake DTC 0xa6f8e0 Turn ignition OFF and wait until compressor temperature is below 85 C Perform a test drive to check if the error is being raised again Is the error...

Page 393: ...ion Possible Causes Possible Solutions iAPU has reported low air pressure in the primary brake circuit 1 Air leak in primary brake circuit 2 iAPU internal failure 3 Air brake compressor internal failu...

Page 394: ...r Yes No Defective iAPU Replace iAPU Check that the air brake compressor is running Is the air brake compressor running Yes No Are any error messages related to the air brake compressor being raised o...

Page 395: ...leaks and refill the air tanks by turning ignition ON Inspect the iAPU for air leaks Are there any air leaks Yes No Defective iAPU Replace iAPU Is the same error message being raised again on next ign...

Page 396: ...n Possible Causes Possible Solutions iAPU has reported low air pressure in the secondary brake circuit 1 Air leak in secondary brake circuit 2 iAPU internal failure 3 Air brake compressor internal fai...

Page 397: ...ar Yes No Defective iAPU Replace iAPU Check that the air brake compressor is running Is the air brake compressor running Yes No Are any error messages related to the air brake compressor being raised...

Page 398: ...leaks and refill the air tanks by turning ignition ON Inspect the iAPU for air leaks Are there any air leaks Yes No Defective iAPU Replace iAPU Is the same error message being raised again on next ig...

Page 399: ...o refill 2 Replace iAPU HMI displays or logs Fault code F0002 and Air brake DTC 0xd4f9e2 Are air pressures in both air tanks less than 4 bar Deplete the pressure in both air tanks to less than 4 bar P...

Page 400: ...olutions iAPU has reported low air pressure in the parking brake circuit 1 Software error 1 Contact Dana This feature is not used If this error is raised the technician should contact Dana HMI display...

Page 401: ...Solutions iAPU has reported low air pressure in the auxiliary circuit 1 Software error 1 Contact Dana This feature is not used If this error is raised the technician should contact Dana HMI displays...

Page 402: ...es Possible Solutions iAPU has reported low air pressure in circuit 5 1 iAPU internal failure 1 Replace iAPU HMI displays or logs Fault code F0002 and Air brake DTC 0xe4f9e4 Circuit 5 is not configure...

Page 403: ...this connector is unplugged the HVIL will be broken and the air brake compressor will send an error message via CAN The air brake compressor is also connected to the analog HVIL which is a physical c...

Page 404: ...ect in the HVIL analog circuit Yes No Contact Dana for further investigation Repair as prescribed in the in subtree Does the HMI also display F0063 F0062 F0061 Yes No Continued on next page WARNING El...

Page 405: ...onnector Replace harness Is there any evidence of continuity loss Yes Defective harness Replace harness No Contact Dana for further investigation Continued from previous page With a multimeter check f...

Page 406: ...used by defective LV harness or connector 3 CAN communication problem 4 Air brake compressor internal failure 1 Replace 24V fuse F2 2 Replace LV connector or harness per Service Manual 3 Resolve CAN c...

Page 407: ...mpressor No contact Disconnect connector C202 from air brake compressor Refer to the connector investigation subtree Inspect fuse F2 in the 24V fuse box C20 Is fuse F2 blown or intermittent No Yes A C...

Page 408: ...e connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual Continued from previous page Remove fuse F2 in order to tak...

Page 409: ...integrity Refer to the connector investigation subtree Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Serv...

Page 410: ...gain during a test drive No Yes No With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires betwee...

Page 411: ...harness or connector 4 CAN communication problem 5 iAPU internal failure 1 Replace 24V fuse F2 2 Replace 12V fuse F9 3 Replace LV connector or harness per Service Manual 4 Resolve CAN communication pr...

Page 412: ...ting HMI displays Air Dryer No Contact Disconnect connectors C203 C204 and C206 from iAPU Inspect fuse F2 in the 24V fuse box C20 Is fuse F2 blown or intermittent No Yes A Continued on next page Turn...

Page 413: ...page Continued on next page With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms iAPU C206S Connector pin Ground Pin 2 Ground iAPU C...

Page 414: ...nvestigation subtree Investigate CAN A network Is the error still raised Yes No Complete Contact Dana for further investigation Is there any evidence of continuity loss Yes Defective harness Replace h...

Page 415: ...r integrity Refer to the connector investigation subtree Yes Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Servi...

Page 416: ...gain during a test drive No Yes No With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires betwee...

Page 417: ...t Descriptions DCDC The DCDC converts 650V DC input supplied by the ESS to 24V DC output It consists of a power stage which performs the DC DC conversion and a control stage The control stage is power...

Page 418: ...DCDC input voltage is too low 1 Compatibility problem with aftermarket accessory 2 ESS fault 3 HV fuse F8 blown 4 Loss of continuity caused by defective HV harness or connector 1 Disconnect incompatib...

Page 419: ...ermarket accessories and put the vehicle in ready mode Does the error occur again No Yes Does the HMI also display error F0026 No Yes Refer to error F0026 troubleshooting tree Wait 30 seconds Wait 30...

Page 420: ...lem with the connector integrity Refer to connector investigation subtree Yes No Defective connector Replace harness DCDC C730P Connector pin Pin 1 Pin 2 HV Jct Box C712P Connector pin Pin 2 Pin 1 DCD...

Page 421: ...ion Observing proper safety precautions open the HV junction box Inspect fuse F8 in the HV junction box Is fuse F8 blown or intermittent No Yes Connect connector C712 to HV junction box Continued from...

Page 422: ...specific error HMI displays or logs Fault code F0008 and DCDC fault reason 2 Check the HMI for other faults Does the HMI also display error F0026 No Yes Refer to error F0026 troubleshooting tree Are...

Page 423: ...and start a stopwatch Are any aftermarket accessories installed on the vehicle No Yes Disconnect all aftermarket accessories and put the vehicle in ready mode HMI displays or logs Fault code F0008 and...

Page 424: ...tween the following points Is the voltage across each battery 12V No Replace faulty battery with a battery that fits the system specifications Yes With a multimeter measure the voltage between the fol...

Page 425: ...or continuity between the following points Continuity Resistance is less than or equal to 2ohms Cable Terminal RT019 RT019 RT020 Cable Terminal RT020 Is there any evidence of continuity loss Yes Defec...

Page 426: ...ry or repair battery wiring Are any aftermarket accessories installed on the vehicle No Yes Disconnect all aftermarket accessories and put the vehicle in ready mode HMI displays or logs Fault code F00...

Page 427: ...g drawn on the LV network 1 Compatibility problem with aftermarket accessory 2 Overcurrent due to very high power steering demand 3 Short circuit in LV harness or connector 1 Disconnect incompatible a...

Page 428: ...10 troubleshooting tree Disconnect screw terminal RT008 from the DCDC Is there any evidence of a short circuit within the harness Yes No With a multimeter check for short circuit between the following...

Page 429: ...ossible Causes Possible Solutions DCDC has detected that the DCDC internal temperature is too high 1 Cooling system problem 1 Resolve cooling system problem HMI displays or logs Fault code F0008 and D...

Page 430: ...iption Possible Causes Possible Solutions DCDC has detected an internal failure which requires support from Dana 1 DCDC internal failure 1 Contact Dana HMI displays or logs Fault code F0008 and DCDC f...

Page 431: ...communication failure on the CAN network 1 CAN communication problem 1 Resolve CAN communication problem HMI displays or logs Fault code F0008 and DCDC fault reason 8 Refer to the CAN Investigation s...

Page 432: ...iption Possible Causes Possible Solutions DCDC has detected an internal failure which requires support from Dana 1 DCDC internal failure 1 Contact Dana HMI displays or logs Fault code F0008 and DCDC f...

Page 433: ...ccessory 2 Overcurrent due to very high power steering demand 3 Short circuit in LV harness or connector 1 Disconnect incompatible accessory 2 Error should self correct when power steering load return...

Page 434: ...iption Possible Causes Possible Solutions DCDC has detected an internal failure which requires support from Dana 1 DCDC internal failure 1 Contact Dana HMI displays or logs Fault code F0008 and DCDC f...

Page 435: ...essory 2 Overcurrent due to very high power steering demand 3 Short circuit in LV harness or connector 1 Disconnect incompatible accessory 2 Error should self correct when power steering load returns...

Page 436: ...sconnect incompatible accessory 2 Replace low voltage battery or repair battery wiring This error indicates that the DCDC has disabled its LV output because it detected that the output voltage is too...

Page 437: ...le Solutions DCDC has detected reverse polarity on its output 1 Compatibility problem with aftermarket accessory 2 At least one low voltage battery defective not to spec or wired incorrectly 1 Disconn...

Page 438: ...y mode Does the error still appear Yes No Potential compatibility issue with aftermarket accessories Continued on next page Are both batteries the correct voltage 12V and specification No Replace faul...

Page 439: ...t the battery wiring The positive terminal on battery 2 should be wired to the DCDC output RT008 The negative terminal on battery 1 should be wired to the chassis ground If in doubt disconnect the wir...

Page 440: ...multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms Cable Terminal RT019 RT019 RT020 Cable Terminal RT020 Is there any evidence of contin...

Page 441: ...voltage and VCU input voltage 1 Compatibility problem with aftermarket accessory 2 At least one low voltage battery defective not to spec or wired incorrectly 3 Defective LV harness between DCDC and V...

Page 442: ...troubleshooting tree Does the HMI also display F0008 DCDC fault reason 4 No Yes Refer to error F0008 DCDC fault reason 4 troubleshooting tree Are any aftermarket accessories installed on the vehicle N...

Page 443: ...llowing points Is the voltage across each battery 12V No Replace faulty battery with a battery that fits the system specifications Yes With a multimeter measure the voltage between the following point...

Page 444: ...Dana for further investigation A With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms 12V fuse box C14 A5 A5 Pin 65 VCU C651 A Conne...

Page 445: ...multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms Cable Terminal RT019 RT019 RT020 Cable Terminal RT020 Is there any evidence of contin...

Page 446: ...otor controller input voltage 1 Compatibility problem with aftermarket accessory 2 At least one low voltage battery defective not to spec or wired incorrectly 3 Defective LV harness between DCDC and E...

Page 447: ...troubleshooting tree Does the HMI also display F0008 DCDC fault reason 4 No Yes Refer to error F0008 DCDC fault reason 4 troubleshooting tree Are any aftermarket accessories installed on the vehicle N...

Page 448: ...llowing points Is the voltage across each battery 12V No Replace faulty battery with a battery that fits the system specifications Yes With a multimeter measure the voltage between the following point...

Page 449: ...ohms DCDC RT008 Screw terminal RT008 RT012 LOTO Switch RT012 Screw terminal Pin 2 RT097 LOTO Switch RT010 Screw terminal EHPS Inverter RT097 Screw terminal Is the voltage 24V No Yes Continued from pre...

Page 450: ...multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms Cable Terminal RT019 RT019 RT020 Cable Terminal RT020 Is there any evidence of contin...

Page 451: ...HMI also display error F0059 or F0060 No Yes Refer to the corresponding troubleshooting tree Refer to the cooling system investigation subtree Does the HMI also display error F0008 DCDC fault reason 1...

Page 452: ...HV harness The purpose of the HVIL is to provide a warning if any HV connector is unplugged without the HV distribution being safely ended The DCDC monitors continuity between the HVIL pins on its HV...

Page 453: ...lts Does the HMI also display error F0061 F0062 or F0063 No Yes A Disconnect connector C730 from DCDC No Yes Plug it in and restart the vehicle Is connector C730 unplugged Continued on next page WARNI...

Page 454: ...tween the following points Continuity Resistance is less than or equal to 2ohms DCDC C730P Connector pin Pin 3 Pin 4 DCDC C730P Connector pin Is there any problem with the connector integrity Refer to...

Page 455: ...box No Yes Plug it in and restart the vehicle Is connector C730 or C712 unplugged Inspect connector C730 on DCDC and connector C712 on HV junction box A Continued on next page WARNING Electrical haza...

Page 456: ...Resistance is less than or equal to 2ohms DCDC C730P Connector pin Pin 3 Pin 4 DCDC C730P Connector pin Pin 3 Pin 4 HV Jct Box C712P Connector pin HV Jct Box C712P Connector pin Is there any problem...

Page 457: ...use F12 3 Replace LV connector or harness per Service Manual 4 Resolve CAN communication problem The DCDC also monitors CAN connectivity and will raise its own error F0008 DCDC fault reason 8 if it de...

Page 458: ...in order to take continuity measures from inside the fuse box Inspect fuse F3 in the 24V fuse box C20 Is fuse F3 blown or intermittent Yes No Inspect fuse F12 in the 24V fuse box C20 Is fuse F12 blow...

Page 459: ...ual to 2ohms DCDC C84 Connector pin Pin 1 C2 24V fuse box C20 Terminal Pin 7 A3 DCDC C84 Connector pin 24V fuse box C20 Terminal Is there any problem with the connector integrity Yes No Defective conn...

Page 460: ...460 Troubleshooting Is the error still being raised on further key ON cycles Yes No Complete Contact Dana for further investigation Continued on next page...

Page 461: ...drive No Turn ignition OFF and disconnect F3 from 24V fuse box C20 Refer to connector investigation subtree Disconnect connector C84 from DCDC Is there any problem with the connector integrity Yes Def...

Page 462: ...es Defective harness Replace harness No With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires b...

Page 463: ...drive No Turn ignition OFF and disconnect F12 from 24V fuse box C20 Refer to connector investigation subtree Disconnect connector C84 from DCDC Is there any problem with the connector integrity Yes D...

Page 464: ...ng points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends DCDC C84 Connector pin Pin 1 Ground Ground Is there an...

Page 465: ...qualizer is to maintain an equal level of charge between the two low voltage batteries and to ensure the correct voltage is distributed on the 12V and 24V networks MPDM The Multiplex Power Distributio...

Page 466: ...nnector and pin details for each error code are provided in the table below The technician should use the table to look up the information corresponding to the specific error code and then use this in...

Page 467: ...467 Troubleshooting Connector C3 Connector C10 Connector C11 black Connector C12 gray Connector C22 Connector C23...

Page 468: ...468 Troubleshooting Connector C44 Connector C45 Connector C53 Connector C54 Connector C661...

Page 469: ...hich fuse to check Turn ignition OFF Is the suspect fuse blown or intermittent No Yes Defective MPDM Replace the MDPM Disconnect the low voltage connection as the device that is associated with the bl...

Page 470: ...ntification Location and Service Chart in the Service Manual Refer to the connector investigation subtree Did the fuse blow again Yes No Reconnect the harness to the device Turn ON the ignition to rea...

Page 471: ...ace the defective fuse Complete Does the error still occur on further ignition cycles No Yes Repeat the trouble tree steps With a multimeter check for short circuit between the following points LV sho...

Page 472: ...owing points MPDM C10 Connector Pin 1 Pin 3 MPDM C10 Connector MPDM C10 Connector Pin 8 Pin 3 MPDM C10 Connector Refer to the connector investigation subtree Refer to the connector investigation subtr...

Page 473: ...ual to 2ohms MPDM C10 Connector Pin 1 Pin A MPDM C12 Connector MPDM C10 Connector Pin 3 Pin 4 Ground C10 Connector Pin 4 Pin 4 Pin 9 Pin 4 Pin 10 Pin 4 Pin 8 A1 MPDM C10 Connector 12V fuse box C14 Ter...

Page 474: ...ing tree is provided The specific fuse relay connector and pin details for each error code are provided in the table below The technician should use the table to look up the information corresponding...

Page 475: ...475 Troubleshooting Connector C3 Connector C10 Connector C11 black Connector C12 gray Connector C22 Connector C23...

Page 476: ...476 Troubleshooting Connector C44 Connector C45 Connector C53 Connector C54 Connector C661...

Page 477: ...rror message Refer to the MPDM Table to determine which fuse and relay to check Turn ignition OFF Is the fuse blown or intermittent Yes No Replace relay in the MPDM and restart the truck Does the HMI...

Page 478: ...owing points MPDM C10 Connector Pin 1 Pin 3 MPDM C10 Connector MPDM C10 Connector Pin 8 Pin 3 MPDM C10 Connector Refer to the connector investigation subtree No Refer to the connector investigation su...

Page 479: ...al to 2ohms MPDM C10 Connector Pin 1 Pin A MPDM C12 Connector MPDM C10 Connector Pin 3 Pin 4 Ground C100 Connector Pin 4 Pin 4 Pin 9 Pin 4 Pin 10 Pin 4 Pin 8 A1 MPDM C10 Connector 12V fuse box C14 Ter...

Page 480: ...LV distribution network to three phase AC output to power the motor The control stage is powered by 24V DC voltage It is connected to the CAN network and receives data from the motor through an LV fe...

Page 481: ...m the EHPS motor controller Result through use of the Dana TM4 EHPS Motor Controller MI06 Troubleshooting Guide EHPS service codes 2407 2801 2802 2803 3402 3403 3603 3605 3608 3609 3607 3701 3702 3705...

Page 482: ...s that the power steering system is not operable 1 Defective EHPS motor controller 1 Replace EHPS motor controller HMI displays or logs Fault code F0010 F0011 F0012 F0013 F0014 and EHPS service code 0...

Page 483: ...405 2406 HMI displays or logs Fault code F0010 F0011 F0012 F0013 F0014 and EHPS service code 2402 2403 2404 2405 2406 Turn ignition OFF When troubleshooting these EHPS service codes the technician is...

Page 484: ...uide Inspect the power steering oil circuit for leaks and clogs Are there any leaks or clogs in the power steering oil circuit No Repair the circuit accordingly Yes Inspect the pump for possible defec...

Page 485: ...oes the pump seem unable to turn properly Yes No Replace EHPS pump and motor assembly If no external system was found responsible for the failure and the root cause couldn t be found in the TM4 troubl...

Page 486: ...e code 3604 3707 Error Description Possible Causes Possible Solutions The EHPS motor controller detects that the power steering system is not operable 1 Causes covered in TM4 power steering troublesho...

Page 487: ...or further investigation No When troubleshooting fault reason 3604 3707 the technician is instructed to check the LV distribution network for root causes Does the HMI also display F0095 or F0008 Yes N...

Page 488: ...ee Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points Yes No Clean connectors according to the ins...

Page 489: ...de Fault Reason 3610 Error Description Possible Causes Possible Solutions The EHPS motor controller detects that the power steering system is not operable 1 Causes covered in TM4 power steering troubl...

Page 490: ...n network for root causes Have error code F0059 F0060 F0020 F0000 or F0008 been raised simultaneously Yes Contact Dana for further investigation No Does the HMI also display F0095 or F0008 Yes No Refe...

Page 491: ...ee Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points Yes No Clean connectors according to the ins...

Page 492: ...e code 3703 3704 Error Description Possible Causes Possible Solutions The EHPS motor controller detects that the power steering system is not operable 1 Causes covered in TM4 power steering troublesho...

Page 493: ...tribution network for root causes Have error code F0059 F0060 F0020 F0000 or F0008 been raised simultaneously Yes Contact Dana for further investigation No Does the HMI also display F0095 or F0008 Yes...

Page 494: ...e Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points Yes No Clean connectors according to the inst...

Page 495: ...vice code 3802 Error Description Possible Causes Possible Solutions The EHPS motor controller detects that the power steering system is not operable 1 Causes covered in TM4 power steering troubleshoot...

Page 496: ...n network for root causes Have error code F0059 F0060 F0020 F0000 or F0008 been raised simultaneously Yes Contact Dana for further investigation No Does the HMI also display F0095 or F0008 Yes Refer t...

Page 497: ...e Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points Yes No Clean connectors according to the inst...

Page 498: ...tem 1 Possible CAN communication error 1 Troubleshoot the CAN D network HMI displays or logs Fault code F0010 F0011 F0012 F0013 F0014 and EHPS service code 4301 4302 Were you able to find a problem in...

Page 499: ...tem 1 Possible CAN communication error 1 Troubleshoot the CAN D network HMI displays or logs Fault code F0010 F0011 F0012 F0013 F0014 and EHPS service code 5001 Were you able to find a problem in the...

Page 500: ...rload 3 Ambient temperature exceeds 50 C Inspect the power steering oil circuit for leaks and clogs Are there any leaks or clogs in the power steering oil circuit No Repair the circuit accordingly Yes...

Page 501: ...60 F0020 F0000 F0096 or F0008 been raised simultaneously Yes No If no external system was found responsible for the failure and the root cause couldn t be found in the TM4 troubleshooting guide then t...

Page 502: ...rload 3 Ambient temperature exceeds 50 C Inspect the power steering oil circuit for leaks and clogs Are there any leaks or clogs in the power steering oil circuit No Repair the circuit accordingly Yes...

Page 503: ...oes the pump seem unable to turn properly Yes Replace EHPS pump and motor assembly No If no external system was found responsible for the failure and the root cause couldn t be found in the TM4 troubl...

Page 504: ...rload 3 Ambient temperature exceeds 50 C Inspect the power steering oil circuit for leaks and clogs Are there any leaks or clogs in the power steering oil circuit No Repair the circuit accordingly Yes...

Page 505: ...oes the pump seem unable to turn properly Yes Replace EHPS pump and motor assembly No If no external system was found responsible for the failure and the root cause couldn t be found in the TM4 troubl...

Page 506: ...401 Error Description Possible Causes Possible Solutions The EHPS motor controller detects a problem resulting in possible failure of the power steering system 1 Causes covered in TM4 power steering t...

Page 507: ...oting Guide for code 5401 Have error code F0059 F0060 F0020 F0000 or F0008 been raised simultaneously Yes Contact Dana for further investigation No Does the HMI also display F0095 or F0008 Yes No Refe...

Page 508: ...e Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points Yes No Clean connectors according to the inst...

Page 509: ...vice code 5402 Error Description Possible Causes Possible Solutions The EHPS motor controller detects that the power steering system is not operable 1 Causes covered in TM4 power steering troubleshoot...

Page 510: ...or Is there any evidence of a defect between the pins of the relay No Yes Defective relay Replace relay Refer to relay investigation subtree Investigate relay K008 Have error code F0059 F0060 F0020 F0...

Page 511: ...gation subtree Defective wiring Replace wiring Inspect all connection points between the EHPS motor controller and the batteries Can you find any traces of burnt or corrosion on the connection points...

Page 512: ...k 1 EHPS motor controller DCDC or LV distribution fault 2 EHPS motor controller internal failure 1 Troubleshoot specific error 2 Replace EHPS motor controller Does the HMI also display F0011 F0012 or...

Page 513: ...fective relay K015 5 CAN communication problem 6 EHPS motor controller internal failure 1 Replace 24V fuse F10 2 Replace 12V fuse F13 3 Replace LV connector or harness per Service Manual 4 Replace rel...

Page 514: ...514 Troubleshooting Connector C676 Connector C651 B Circuit73...

Page 515: ...HPS motor controller Refer to the connector investigation subtree Is fuse F10 on 12V fuse box C14 blown or intermittent No Yes A B Continued on next page With a multimeter measure the voltage between...

Page 516: ...ty Resistance is less than or equal to 2ohms 24V fuse box C20 Terminal C3 Pin 1 Relay K015 C38 Connector 12V fuse box C14 Terminal A10 Pin 5 Relay K015 C38 Connector Pin 4 Pin 2 Relay K015 C38 Connect...

Page 517: ...s Defective harness Replace harness Contact Dana for further investigation Continued from previous page Is there any evidence of a defect between the pins of the relay No Yes Defective relay Replace r...

Page 518: ...st points of the harness ends 24V fuse box C20 Terminal C3 GND strip1 Ground A Disconnect blown fuse F13 from 24V fuse box C20 Replace fuse F13 on 24V fuse box C20 Restart the vehicle Complete Did fus...

Page 519: ...y evidence of a defect between the pins of the relay No Yes Defective relay Replace relay Refer to relay investigation subtree Investigate relay K015 Did fuse F13 blow again during test drive No Yes C...

Page 520: ...rness ends 12V fuse box C14 Terminal A10 GND strip1 Ground B Disconnect blown fuse F10 from 12V fuse box C14 Replace fuse F10 on 12V fuse box C14 Restart the vehicle Complete Did fuse F10 blow again d...

Page 521: ...y evidence of a defect between the pins of the relay No Yes Defective relay Replace relay Refer to relay investigation subtree Investigate relay K015 Did fuse F10 blow again during test drive No Yes C...

Page 522: ...this troubleshooting guide A C Compressor The A C compressor is between the evaporator and condenser Its function is to compress and superheat the refrigerant which is in vapor phase before it enters...

Page 523: ...al failure 1 Troubleshoot specific error 2 Replace cabin heater The technician should check for overheating F0133 as this could trigger other errors Otherwise the heater needs to be replaced HMI displ...

Page 524: ...t condition 1 A C fault 2 Blown HV fuse F5 3 Cabin heater internal failure 1 Troubleshoot specific error 2 Replace HV fuse F5 3 Replace cabin heater An overcurrent condition may occur if the A C compr...

Page 525: ...ion Check the fuse F5 in the HV junction box Is the heater operating No Yes Complete Does the HMI still display F0053 Cabin heating system fault Fault reason 3 Yes No Is fuse F5 blown or intermittent...

Page 526: ...ater pump fault 2 Low fluid level leak obstruction or air lock in heating circuit 3 Cabin heater internal failure 1 Troubleshoot specific error 2 Resolve low fluid level leak obstruction or air lock i...

Page 527: ...nector 4 Blown HV fuse F5 5 Defective HV harness or connector 6 Cabin heater internal failure 1 Troubleshoot specific error 2 Replace 12V fuse F13 3 Replace LV connector or harness per Service Manual...

Page 528: ...or F0026 troubleshooting tree Inspect fuse F13 in the 12V fuse box C14 Place the vehicle in accessory mode Is error F0054 still raised No Yes Troubleshoot the high voltage Add the correct section here...

Page 529: ...Service Chart in the Service Manual With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms C73 Heater Connector pin Pin 1 C3 12V fuse...

Page 530: ...to connector investigation subtree No Yes Defective connector Replace harness Heater C721P Connector pin Pin 1 Pin 2 HV Jct Box C709P Connector pin Pin 2 Pin 1 Heater C721P Connector pin HV Jct Box C7...

Page 531: ...s fuse F5 blown No Yes With a multimeter check for short circuit between the following points HV short Resistance measurement is less than 350k ohms Inspect all connectors and wires between the two te...

Page 532: ...a short circuit within the harness Yes Defective harness Replace harness No Defective heater Replace heater Replace fuse F5 Always inform DANA when replacing a fuse in the HV junction box Close HV jun...

Page 533: ...estigation subtree Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual A Continued on next page...

Page 534: ...s between the two test points of the harness ends C73 Heater Connector pin Pin 1 Ground Ground Is there any evidence of a short circuit within the harness Defective harness Replace harness Yes No Cont...

Page 535: ...ondition 1 Low fluid level or leak in heating circuit 2 Cabin heater pump internal failure 1 Repair and or refill heating circuit 2 Replace cabin heater pump HMI displays or logs Fault code F0055 Refe...

Page 536: ...3 Blown 24V fuse F4 4 Blown 24V fuse F5 5 Blown 24V fuse F14 6 Blown 24V fuse F15 7 Loss of continuity due to defective LV connector or harness 8 Condenser fan 1 or 2 internal failure 1 Clear obstruc...

Page 537: ...troubleshooting tree Visually inspect condenser fan 1 and 2 Is either fan damaged obstructed or otherwise unable to turn freely Yes Clear obstruction or replace fan Inspect fuse F4 in the 24V fuse box...

Page 538: ...fan 2 Remove fuse F4 and F14 in order to take continuity measures from inside the fuse box Is fuse F14 blown or intermittent No Yes Is fuse F4 blown or intermittent No Yes Inspect fuse F14 in the 24V...

Page 539: ...onnector pin 24V fuse box C20 Terminal Pin 6 C4 Condenser fan 2 C82 Connector pin Pin 1 A4 24V fuse box C20 Terminal Continued on next page Continued from previous page Is there any evidence of contin...

Page 540: ...blown or intermittent No Yes Is fuse F5 blown or intermittent No Yes Inspect fuse F15 in the 24V fuse box C20 C D Is there any problem with the connector integrity Refer to the connector investigation...

Page 541: ...tinuity Resistance is less than or equal to 2ohms Condenser fan 1 C89 Connector pin Condenser fan 1 C89 Connector pin Pin 3 Pin 4 Condenser fan 1 C89 Connector pin Pin 8 Ground Ground Condenser fan 1...

Page 542: ...Manual A Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connecto...

Page 543: ...uit within the harness Defective harness Replace harness Yes No Defective condenser fan 2 Replace condenser fan 2 Complete Did fuse F4 blow again during a test drive No Yes Replace fuse F4 on 24V fuse...

Page 544: ...anual B Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connector...

Page 545: ...it within the harness Defective harness Replace harness Yes No Defective condenser fan 2 Replace condenser fan 2 Complete Did fuse F14 blow again during a test drive No Yes Replace fuse F14 on 24V fus...

Page 546: ...Manual C Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connecto...

Page 547: ...uit within the harness Defective harness Replace harness Yes No Defective condenser fan 1 Replace condenser fan 1 Complete Did fuse F5 blow again during a test drive No Yes Replace fuse F5 on 24V fuse...

Page 548: ...anual D Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connector...

Page 549: ...it within the harness Defective harness Replace harness Yes No Defective condenser fan 1 Replace condenser fan 1 Complete Did fuse F15 blow again during a test drive No Yes Replace fuse F15 on 24V fus...

Page 550: ...ater fault 2 Heater pump fault 3 A C compressor fault 4 Low refrigerant pressure in A C system This can result in reduced performance of the defrost function An error code F0053 F0055 F0134 F0135 F013...

Page 551: ...d level leak obstruction or air lock in heating circuit 3 Replace cabin heater Turn the heater OFF and wait for it to cool down Turn the heater ON Does the HMI also display F0055 F0134 or F0136 No Yes...

Page 552: ...ion 1 Obstruction or air lock in heating circuit 2 Heater pump internal failure 1 Resolve obstruction or air lock in heating circuit 2 Replace heater pump HMI displays or logs Fault code F0134 Refer t...

Page 553: ...in heater internal failure 1 Troubleshoot specific error 2 Resolve low fluid level leak obstruction or air lock in heating circuit 3 Replace heater pump 4 Replace cabin heater HMI displays or logs Fau...

Page 554: ...of continuity due to defective LV connector or harness 4 Wrong fluid used in heating circuit 5 Air lock in heating circuit 6 Heater pump internal failure 1 Troubleshoot specific error 2 Replace 12V f...

Page 555: ...te the heater pump If the heater was used recently wait for components to cool down Is the fluid in the heating circuit the correct specification No Yes Drain and flush heating circuit Refill with cor...

Page 556: ...r pump by using the service interface to activate the pump Does fluid flow out of the outlet when the pump is running No Yes Reconnect the hose to the pump outlet Refill fluid as needed Is the heating...

Page 557: ...problem resolved Yes No Disconnect the heating circuit one section at a time and check for obstructions Complete Is the heating circuit obstructed Yes No Clear obstruction reconnect hoses and refill f...

Page 558: ...pump Disconnect connector C651 B from VCU Remove fuse F15 in order to take continuity measures from inside the fuse box Refer to the connector investigation subtree No A B Continued on next page WARNI...

Page 559: ...651 B Connector pin Is there any evidence of continuity loss Defective harness Replace harness Yes No Is there any problem with the connector integrity Defective connector Replace the connector as des...

Page 560: ...vice Manual B Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all con...

Page 561: ...ircuit within the harness Defective harness Replace harness Yes No Defective heater pump Replace heater pump Complete Did fuse F15 blow again during a test drive No Yes Replace fuse F15 on 12V fuse bo...

Page 562: ...4 Defective wiring to pressure sensor 1 Troubleshoot specific error 2 Repair and or recharge A C system 3 Replace pressure sensor 4 Replace LV connector or harness per Service Manual This error indic...

Page 563: ...logs Fault code F0141 Does the HMI also display A C compressor fault or A C compressor no contact No Yes Refer to the corresponding error troubleshooting tree Is the refrigerant pressure lower than e...

Page 564: ...fer to the connector investigation subtree Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual P...

Page 565: ...eplace HV harness 3 Replace A C compressor The purpose of the HVIL is to provide a warning if any HV connector is unplugged without the HV distribution being safely ended The A C compressor monitors c...

Page 566: ...de F0142 Inspect connector C729 on A C compressor Does the HMI also display F0061 F0062 or F0063 No Yes A Continued on next page WARNING Electrical hazard Follow Safety Warnings and High Voltage Shutd...

Page 567: ...e With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms AC compressor C729P Connector pin Pin 3 Pin 4 AC compressor C729P Connector p...

Page 568: ...box No Yes Plug it in and restart the vehicle Is connector C729 or C710 unplugged Inspect connector C729 on A C compressor and connector C710 on HV junction box A Continued on next page WARNING Elect...

Page 569: ...ess than or equal to 2ohms AC compressor C729P Connector pin Pin 3 Pin 4 AC compressor C729P Connector pin Pin 3 Pin 4 HV Jct Box C710P Connector pin HV Jct Box C710P Connector pin Is there any proble...

Page 570: ...r Description Possible Causes Possible Solutions Not currently implemented The VCU has detected a discontinuity in the high voltage interlock loop HVIL at the heater 1 VCU software error 1 Contact Dan...

Page 571: ...ition 1 ESS fault 2 Defective LV connector or harness 3 Blown HV fuse F6 4 Defective HV connector or harness 5 A C compressor internal failure 1 Troubleshoot specific error 2 Replace LV connector or h...

Page 572: ...er check the voltage between the following points AC compressor C71 Connector pin Pin 3 Pin 6 AC compressor C71 Connector pin Is there any problem with the connector integrity Refer to the connector i...

Page 573: ...he following points Continuity Resistance is less than or equal to 2ohms AC compressor C729P Connector pin Pin 1 Pin 1 HV Jct Box C710P Connector pin Pin 2 Pin 2 Is there any problem with the connecto...

Page 574: ...Continued from previous page Continued on next page Is fuse F6 blown or intermittent No Yes Is error F0158 still raised No Yes Complete Contact Dana for further investigation Refer to the CAN Investi...

Page 575: ...A C compressor Replace A C compressor Continued from previous page With a multimeter check for short circuit between the following points HV short Resistance measurement is less than 350k ohms Inspect...

Page 576: ...se F15 4 Loss of continuity caused by defective LV harness or connector 5 Condenser fan 1 internal failure 1 Resolve CAN communication problem 2 Replace 24V fuse F5 3 Replace 24V fuse F15 4 Replace LV...

Page 577: ...nspect fuse F5 in the 24V fuse box C20 Is fuse F15 blown or intermittent No Yes Is fuse F5 blown or intermittent No Yes Inspect fuse F15 in the 24V fuse box C20 A B Is there any problem with the conne...

Page 578: ...Connector pin Pin 8 Ground Ground Condenser fan 1 C89 Connector pin 24V fuse box C20 Terminal Pin 6 C5 Condenser fan 1 C89 Connector pin Pin 1 A5 24V fuse box C20 Terminal Continued from previous pag...

Page 579: ...Manual A Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connecto...

Page 580: ...uit within the harness Defective harness Replace harness Yes No Defective condenser fan 1 Replace condenser fan 1 Complete Did fuse F5 blow again during a test drive No Yes Replace fuse F5 on 24V fuse...

Page 581: ...anual B Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connector...

Page 582: ...it within the harness Defective harness Replace harness Yes No Defective condenser fan 1 Replace condenser fan 1 Complete Did fuse F15 blow again during a test drive No Yes Replace fuse F15 on 24V fus...

Page 583: ...e F14 4 Loss of continuity caused by defective LV harness or connector 5 Condenser fan 2 internal failure 1 Resolve CAN communication problem 2 Replace 24V fuse F4 3 Replace 24V fuse F14 4 Replace LV...

Page 584: ...nect connector C82 from condenser fan 2 Remove fuse F4 and F14 in order to take continuity measures from inside the fuse box Inspect fuse F4 in the 24V fuse box C20 Is fuse F14 blown or intermittent N...

Page 585: ...ctor Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual Condenser fan 2 C82 Connector pin Condenser fan 2 C82 Connector pi...

Page 586: ...gation subtree Investigate CAN C network Is the error still raised Yes No Complete Defective condenser fan 2 Replace condenser fan 2 Is there any evidence of continuity loss Yes Defective harness Repl...

Page 587: ...Manual A Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connecto...

Page 588: ...uit within the harness Defective harness Replace harness Yes No Defective condenser fan 2 Replace condenser fan 2 Complete Did fuse F4 blow again during a test drive No Yes Replace fuse F4 on 24V fuse...

Page 589: ...anual B Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connector...

Page 590: ...it within the harness Defective harness Replace harness Yes No Defective condenser fan 2 Replace condenser fan 2 Complete Did fuse F14 blow again during a test drive No Yes Replace fuse F14 on 24V fus...

Page 591: ...fuse F12 3 Loss of continuity caused by defective LV harness or connector 4 A C compressor internal failure 1 Resolve CAN communication problem 2 Replace 12V fuse F12 3 Replace LV connector or harness...

Page 592: ...continuity measures from inside the fuse box Refer to the connector investigation subtree Inspect fuse F12 in the 12V fuse box C14 Is fuse F12 blown or intermittent No Yes Continued on next page A WA...

Page 593: ...Replace harness No With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms AC compressor C71 Connector pin Pin 6 C2 12V fuse box C14 T...

Page 594: ...anual A Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connector...

Page 595: ...uit within the harness Defective harness Replace harness Yes Defective A C compressor Replace A C compressor No Complete Did fuse F12 blow again during a test drive No Yes Replace fuse F12 on 12V fuse...

Page 596: ...by defective LV harness or connector 4 Cabin heater internal failure 5 CAN LIN internal failure 1 Resolve CAN communication problem 2 Replace 12V fuse F13 3 Replace LV connector or harness per Service...

Page 597: ...order to take continuity measures from inside the fuse box Refer to the connector investigation subtree Inspect fuse F13 in the 12V fuse box C14 Is fuse F13 blown or intermittent No Yes Continued on...

Page 598: ...connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual CAN LIN C72 Connector pin Ground Pin 6 Ground CAN LIN C72 Con...

Page 599: ...nvestigation subtree Investigate CAN C network Is there any evidence of continuity loss Yes Defective harness Replace harness No Is the error still raised Yes No Complete Contact Dana for further inve...

Page 600: ...to the connector investigation subtree Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual A Co...

Page 601: ...ter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends Heater...

Page 602: ...erface HMI is an interactive display in the cab which allows the driver or maintenance operator to perform vehicle control functions as well as access operational data and error messages It is powered...

Page 603: ...ault Supervisory controller requests shutdown This message is expected to be accompanied by the specific error that triggered the warning either F0026 BMS fault or F0051 F0052 Supervisory controller s...

Page 604: ...Supervisory controller 1 Contact Dana The Supervisory controller will take this action as a last line of defense if a shutdown is not requested by another device BMS Traction inverter or VCU Given th...

Page 605: ...hibited Error Description Possible Causes Possible Solutions VCU has detected a malfunction in the HV distribution system which requires support from Dana 1 HV distribution internal error 1 Contact Da...

Page 606: ...S Box will open to isolate the high voltage battery packs from the HV distribution system The VCU will notify the driver immediately by raising error F0058 and will prohibit restarting the vehicle If...

Page 607: ...607 Troubleshooting Connector C367P pin Connector C367S socket Connector C676 Connector C651 B Circuit73...

Page 608: ...hooting tree Disconnect connector C11 from MPDM Disconnect connector C93 Disconnect connector C75 Disconnect connector C76 Disconnect connector C367 Disconnect connector C40 Disconnect connector C50 D...

Page 609: ...nnector pin Pin G Pin 12 C93S C75 Connector pin Connector pin Pin 7 Pin 1 C93S C76 Connector pin Connector pin Pin 5 Pin 1 Pin 8 Pin 4 Pin 6 Pin 4 C93P C40S Connector pin Connector pin Pin 8 Pin 11 Pi...

Page 610: ...g points Continuity Resistance is less than or equal to 2ohms VCU C651 B Connector Pin 41 Pin 17 C676P Connector C91S Connector Pin 17 Pin 32 C40S Connector C40P Connector Pin 32 Pin 10 C367S Connecto...

Page 611: ...investigation subtree Investigate relays K006 and K007 Continued from previous page Contact Dana for further investigation Were you able to find a problem in the CAN A network Yes No Refer to CAN inv...

Page 612: ...ree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the ha...

Page 613: ...est drive No Yes Contact Dana for further investigation Complete Is there any evidence of a short circuit within the harness Yes Defective harness Replace harness No Replace fuse F20 on 12V fuse box C...

Page 614: ...connectors on the vehicle If a connector is unplugged unsafely the HVIL will be broken and the VCU will detect the loss of signal voltage on the circuit Because the analog HVIL is a single series circ...

Page 615: ...play F0026 F0139 F0140 F0142 F0143 F0144 F0146 Yes No Refer to the specific error troubleshooting tree Refer to the Analog HVIL investigation subtree Could you find any defect in the HVIL analog circu...

Page 616: ...icle If a connector is unplugged unsafely the HVIL will be broken and the VCU will detect the loss of signal voltage on the circuit Because the analog HVIL is a single series circuit the VCU will dete...

Page 617: ...F0063 Does the HMI also display F0061 Yes No Refer to the specific error troubleshooting tree Resume operation of the truck if the error is raised again stop the truck and refer F0061 troubleshooting...

Page 618: ...1 Troubleshoot specific error This error should be accompanied by the BMS error F0026 that triggered the shutdown If error F0092 appears alone the technician should contact Dana for further investigat...

Page 619: ...uit due to defective LV connector or harness 5 Loss of continuity due to damaged corroded or loose LV bolted connection 6 At least one low voltage battery defective not to spec or wired incorrectly 7...

Page 620: ...N no contact with DCDC error been raised previous to this error being raised Refer to the specific error troubleshooting tree Yes Refer to the specific error troubleshooting tree No Is fuse F1 blown o...

Page 621: ...k for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends RT020 GND strip...

Page 622: ...38 RT037 RT034 RT016 RT033 RT021 RT007 RT087 RT086 RT027 RT024 Is there any traces of burnt corrosion or a defect affecting the quality of connection on the bolted connections Yes Defective connection...

Page 623: ...for the equalizer to cool down No Is the error being raised again on further key cycles Yes No Complete With an infrared thermometer check the temperature of the equalizer Is the equalizer overheatin...

Page 624: ...ohms Voltage equalizer 12V battery Connector pin Connector pin T1 1 RT005 Voltage equalizer RT011 Connector pin RT034 RT011 RT012 RT013 RT012 RT013 Is there any evidence of a continuity loss along the...

Page 625: ...ge distribution circuit Yes No Defective wiring Replace any defective wiring With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k oh...

Page 626: ...t Yes No Defective wiring Replace any defective wiring Disconnect fuse F2 Disconnect blown fuse F2 Replace fuse F2 Restart the vehicle Complete Did fuse F2 blow again during test drive No Yes B With a...

Page 627: ...ption Possible Causes Possible Solutions An attempt was made to start the vehicle but the vehicle is prohibited from starting due to a cut loop fault 1 Cut loop fault 1 Troubleshoot specific error HMI...

Page 628: ...range 1 Loss of continuity between VCU and temperature sensor due to defective LV connector or harness 2 Defective resistor R006 on temperature sensor circuit 3 Defective temperature sensor 1 Replace...

Page 629: ...s Continuity Resistance is less than or equal to 2ohms VCU C651 B Connector Pin 22 Pin 27 C676P Connector C676P Connector Pin F Pin E C647s Connector C91S Connector Pin 27 Pin 2 C94S Connector Pin 26...

Page 630: ...measure the resistance on the ends of resistance R006 Is the measured resistance around 10K ohms Yes No Defective R006 Replace R006 Refer to PACCAR for sensor investigation and replacement Continued f...

Page 631: ...r 3 Update vehicle with the correct parameters corresponding to the newly installed equipment The vehicle speed is estimated by the VCU based on measurements of the front and rear axle speed If these...

Page 632: ...the HMI showing 0 RPM on the motor speed when driving No Yes Defective traction inverter Replace traction inverter Has the gear ratio or tire size been recently changed to non factory standards Yes N...

Page 633: ...o turn on Error Description Possible Causes Possible Solutions VCU has detected that the heater failed to turn on when requested 1 Low fluid level in heating circuit 2 Heater or heater pump fault 1 Re...

Page 634: ...es Refer to the corresponding error troubleshooting tree Is the blower speed set to 0 No Yes Do you feel air blow from the blower Set the blower speed to 1 Yes Does the HMI still display the error Yes...

Page 635: ...cut loop is a section of LV wiring which can be cut by first responders to shut down the HV system in an emergency The cut loop consists of four wires Three of these supply the BMS and one is used by...

Page 636: ...636 Troubleshooting Connector C676 Connector C651 B Circuit73...

Page 637: ...ent No Yes Does the HMI also display F0058 No Yes Refer to the specific error troubleshooting tree A Disconnect connector C651 B from VCU Disconnect connector C367 Disconnect connector C676 Disconnect...

Page 638: ...Connector Pin 41 Pin 17 C676P Connector C91S Connector Pin 17 Pin 32 C40S Connector C40P Connector Pin 32 Pin 10 C367S Connector Pin 27 Pin 9 C367P Connector Pin 9 Pin 10 C367P Connector C40S Connect...

Page 639: ...ree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the ha...

Page 640: ...est drive No Yes Contact Dana for further investigation Complete Is there any evidence of a short circuit within the harness Yes Defective harness Replace harness No Replace fuse F20 on 12V fuse box C...

Page 641: ...eported 1 Supervisory controller internal error or software error 1 Contact Dana If the contactors were opened due to a legitimate hazard the Supervisory Controller will raise error F0051 instead F014...

Page 642: ...wn was not reported 1 Supervisory controller internal error or software error 1 Contact Dana If the contactors were opened due to a legitimate hazard the Supervisory Controller will raise error F0051...

Page 643: ...visory controller 1 CAN communication problem 1 Resolve CAN communication problem HMI displays or logs Fault code F0150 Were you able to find a problem in the CAN D network Yes No Refer to CAN investi...

Page 644: ...e OnGuard ACC is not supplied by Dana and is not within the scope of this guide For additional troubleshooting refer to the OnGuard documentation HMI displays or logs Fault code F0151 Were you able to...

Page 645: ...lem The OnGuard AEBS is not supplied by Dana and is not within the scope of this guide For additional troubleshooting refer to the OnGuard documentation HMI displays or logs Fault code F0152 Were you...

Page 646: ...valid signal from the accelerator pedal 1 Charge controller supervisory controller software update needed 2 LV distribution or VCU HMI fault 3 CAN communication problem 4 Accelerator pedal fault 1 Upd...

Page 647: ...I also display F0095 or F0104 No Yes Refer to the corresponding troubleshooting tree Were you able to find a problem in the CAN D network Yes No Refer to CAN investigation subtree Investigate CAN D ne...

Page 648: ...ossible Solutions Supervisory controller has detected an invalid signal from the BMS 1 Charge controller supervisory controller software update needed 2 LV distribution or ESS fault 3 CAN communicatio...

Page 649: ...d in the maintenance manual Does the HMI also display BMS No contact No Yes Refer to the BMS No contact troubleshooting tree Were you able to find a problem in the CAN A network Yes No Refer to CAN in...

Page 650: ...ory controller has detected an invalid signal from the DCDC 1 Charge controller supervisory controller software update needed 2 DCDC or LV distribution fault 3 CAN communication problem 1 Update charg...

Page 651: ...the HMI also display BMS No contact No Yes Refer to the BMS No contact troubleshooting tree Were you able to find a problem in the CAN A or CAN B networks Yes No Refer to CAN investigation subtree Inv...

Page 652: ...ervisory controller has detected an invalid signal from the DCDC 1 Charge controller supervisory controller software update needed 2 DCDC or LV distribution fault 3 CAN communication problem 1 Update...

Page 653: ...l Does the HMI also display DCDC No contact No Yes Refer to the DCDC No contact troubleshooting tree Were you able to find a problem in the CAN D network Yes No Refer to CAN investigation subtree Inve...

Page 654: ...Supervisory controller has detected an invalid signal from the Traction inverter 1 Charge controller supervisory controller software update needed 2 Propulsion fault 3 CAN communication problem 1 Upd...

Page 655: ...lso display Traction inverter No contact No Yes Refer to the CAN No Contact with traction inverter troubleshooting tree Were you able to find a problem in the CAN B network Yes No Refer to CAN investi...

Page 656: ...from the hazard light switch 1 Charge controller supervisory controller software update needed 2 VCU HMI fault 3 CAN communication problem 1 Update charge controller supervisory controller software 2...

Page 657: ...pervisory controller software following the procedure provided in the maintenance manual Does the HMI also display Hazard Lamps No contact No Yes Refer to PACCAR further investigation Does the HMI als...

Page 658: ...le to find a problem in the CAN C network Yes No Refer to CAN investigation subtree Investigate CAN C network Repair according to the actions prescribed in the subtree Is the error code still displaye...

Page 659: ...isory controller has detected an invalid HV contactor state signal 1 Charge controller supervisory controller software update needed 2 ESS or VCU HMI fault 3 CAN communication problem 1 Update charge...

Page 660: ...edure provided in the maintenance manual Does the HMI also display F0057 or F0026 No Yes Refer to the corresponding troubleshooting tree Were you able to find a problem in the CAN D and A network Yes...

Page 661: ...Supervisory controller has detected an invalid signal from the VCU 1 Charge controller supervisory controller software update needed 2 VCU HMI or LV distribution fault 3 CAN communication problem 1 Up...

Page 662: ...ual Does the HMI also display F0095 No Yes Refer to the F0095 troubleshooting tree Were you able to find a problem in the CAN D network Yes No Refer to CAN investigation subtree Investigate CAN D netw...

Page 663: ...ntroller has detected an invalid motor torque request signal from the VCU 1 Charge controller supervisory controller software update needed 2 LV distribution fault 3 CAN communication problem 1 Update...

Page 664: ...lowing the procedure provided in the maintenance manual Were you able to find a problem in the CAN B network Yes No Refer to CAN investigation subtree Investigate CAN B network Repair according to the...

Page 665: ...tected an invalid signal from the shift selector 1 Charge controller supervisory controller software update needed 2 CAN communication problem 1 Update charge controller supervisory controller softwar...

Page 666: ...n the maintenance manual Does the HMI also display Gear Shifter No contact No Yes Refer to PACCAR further investigation Were you able to find a problem in the CAN C network Yes No Refer to CAN investi...

Page 667: ...ervisory controller has detected an invalid VREFA or VREFB signal 1 Charge controller supervisory controller software update needed 2 LV distribution fault 3 CAN communication problem 1 Update charge...

Page 668: ...ing the procedure provided in the maintenance manual Does the HMI also display F0095 No Yes Refer to the corresponding troubleshooting tree Were you able to find a problem in the CAN D network Yes No...

Page 669: ...e currently active Error Description Possible Causes Possible solutions VCU internal error 1 Software or calibration error 1 Contact Dana Override currently active is displayed on the HMI Contact Dana...

Page 670: ...act fault messages can be found in the HMI logs by selecting the MC43 2 log Note The Supervisory controller and VCU are both connected to CAN A B C and D networks but communication between the Supervi...

Page 671: ...n three parallel branches One branch runs through the propulsion motor and Traction inverter one branch runs through the DCDC and air brake compressor and one runs through the OBC The radiator and res...

Page 672: ...own 24V fuse F6 3 Blown 24V fuse F16 4 Loss of continuity due to defective LV connector or harness 5 Problem with the cooling circuit leak low coolant etc 6 Powertrain Coolant Pump internal failure 1...

Page 673: ...ector C81 from coolant pump Remove fuse F6 and F16 in order to take continuity measures from inside the fuse box Refer to connector investigation subtree Wait for 10 minutes before operating on the tr...

Page 674: ...r check for continuity between the following points Continuity Resistance is less than or equal to 2ohms Is there any problem with the connector integrity Yes No Defective connector Replace the connec...

Page 675: ...s Complete Did fuse F6 blow again during test drive No Turn ignition OFF and disconnect F6 from 24V fuse box C20 Refer to connector investigation subtree Is there any evidence of a short circuit withi...

Page 676: ...Disconnect blown fuse F16 from 24V fuse box C20 Replace fuse F16 on 24V fuse box C20 Restart the vehicle Complete Did fuse F16 blow again during test drive No Turn ignition OFF and disconnect F16 from...

Page 677: ...to defective LV connector or harness 5 Powertrain Coolant Pump internal failure 1 Troubleshoot specific error 2 Replace 24V fuse F6 3 Replace 24V fuse F16 4 Replace LV connector or harness per Servic...

Page 678: ...ector C81 from coolant pump Remove fuse F6 and F16 in order to take continuity measures from inside the fuse box Refer to connector investigation subtree Wait for 10 minutes before operating on the tr...

Page 679: ...Is there any problem with the connector integrity Yes No Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service M...

Page 680: ...work Is the error still raised Yes No Complete Contact Dana for further investigation Is the coolant level low Yes Refill coolant Check the cooling circuit for leaks Is there any leak in the cooling c...

Page 681: ...es Complete Did fuse F6 blow again during test drive No Turn ignition OFF and disconnect F6 from 24V fuse box C20 Refer to connector investigation subtree Is there any evidence of a short circuit with...

Page 682: ...Disconnect blown fuse F16 from 24V fuse box C20 Replace fuse F16 on 24V fuse box C20 Restart the vehicle Complete Did fuse F16 blow again during test drive No Turn ignition OFF and disconnect F16 fro...

Page 683: ...horted 1 Short circuit in coolant level sensor harness 1 Replace LV connector or harness per Service Manual HMI displays or logs Fault code F0109 Is there any evidence of a short circuit within the ha...

Page 684: ...een Powertrain Coolant Pump and coolant level sensor due to defective LV connector or harness 1 Replace LV connector or harness per Service Manual HMI displays or logs Fault code F0110 Is there any ev...

Page 685: ...se F6 3 Loss of continuity due to defective LV connector or harness 4 Powertrain Coolant Pump internal failure 1 Resolve CAN communication problem 2 Replace 24V fuse F6 3 Replace LV connector or harne...

Page 686: ...connector C81 from coolant pump Remove fuse F6 and F16 in order to take continuity measures from inside the fuse box Refer to connector investigation subtree Wait for 10 minutes before operating on t...

Page 687: ...Location and Service Chart in the Service Manual Refer to the CAN Investigation subtree Investigate CAN D network Is the error still raised Yes No Complete Contact Dana for further investigation With...

Page 688: ...s Complete Did fuse F6 blow again during test drive No Turn ignition OFF and disconnect F6 from 24V fuse box C20 Refer to connector investigation subtree Is there any evidence of a short circuit withi...

Page 689: ...Disconnect blown fuse F16 from 24V fuse box C20 Replace fuse F16 on 24V fuse box C20 Restart the vehicle Complete Did fuse F16 blow again during test drive No Turn ignition OFF and disconnect F16 from...

Page 690: ...lemetry The telemetry module collects data from the vehicle systems and transmits it to remote servers via the modem It is powered by 12V low voltage and communicates via the CAN B network Modem The m...

Page 691: ...4 Blown MPDM fuse F14 5 Loss of continuity due to defective LV connector or harness 6 Defective timed relay 2 1 Resolve CAN communication problem 2 Troubleshoot specific error 3 Replace 12V fuse F14...

Page 692: ...692 Troubleshooting Connector C416 Connector C621 Connector C661 Connector C699P pin Connector C699S socket...

Page 693: ...F14 on 12V fuse box C14 blown or intermittent Inspect fuse F14 on 12V fuse box C14 and fuse F14 on MDPM No Yes Were you able to find a problem in the CAN B network Yes No Refer to CAN investigation su...

Page 694: ...onnector pin C4 Pin 7 Pin 7 Pin 1 C621P C699S Connector pin Connector pin Pin 6 Pin 1 C416S HED C699P HED Connector pin Connector pin Pin F Pin 11 C12 C92S Connector pin Connector pin Pin 11 Pin 11 C6...

Page 695: ...ence of a continuity loss No Yes Defective harness Replace harness Contact Dana for further investigation Replace timer relay 2 Does the HMI still display Telemetry No Contact Turn ignition ON No Comp...

Page 696: ...ector C416 from FleetManagementKit Replace fuse F14 on 12V fuse box C14 Restart the vehicle Complete Did fuse F14 blow again during a test drive No Yes Turn ignition OFF and disconnect F14 from 12V fu...

Page 697: ...oints LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two test points of the harness ends 12V fuse box C14 C4 Connector pin Ground PC4 Ground Contin...

Page 698: ...Complete Did fuse F14 blow again during a test drive No Yes Turn ignition OFF and disconnect F14 from MPDM B Continued on next page Refer to the connector investigation subtree Is there any problem w...

Page 699: ...act Dana for further investigation No Complete With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and...

Page 700: ...700 Troubleshooting ePTO System The electric power take off ePTO system provides an electrical power output which can be used to operate aftermarket onboard accessories...

Page 701: ...defective LV connector or harness 4 Loss of continuity due to defective HV connector or harness 1 Troubleshoot specific error 2 Replace 12V fuse F11 3 Replace LV connector or harness per Service Manu...

Page 702: ...702 Troubleshooting Connector C101 Connector C713 Connector C722 3 4 3 4...

Page 703: ...ic error troubleshooting tree Disconnect connector C6 from ePTO Disconnect connector C15 Remove fuse F11 in order to take continuity measures from inside the fuse box Refer to connector investigation...

Page 704: ...n Connector pin Pin 4 Pin M1 Pin 4 Pin J1 Pin 9 Pin L4 Pin 9 Pin M4 C15S C101 ground Connector pin Connector pin Pin 9 Pin 2 Continued from previous page Continued on next page WARNING Electrical haza...

Page 705: ...e harness Contact Dana for further investigation Continued from previous page With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms H...

Page 706: ...tor investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the two...

Page 707: ...monitors continuity between the HVIL pins on its HV connector C722 If this connector is unplugged unsafely the HVIL will be broken and the ePTO will send an error message via CAN Depending on the ePTO...

Page 708: ...ect in the HVIL analog circuit Yes No Contact Dana for further investigation Repair as prescribed in the in subtree Does the HMI also display F0063 F0062 F0061 Yes No Continued on next page WARNING El...

Page 709: ...Defective connector Replace harness With a multimeter check for continuity between the following points Continuity Resistance is less than or equal to 2ohms ePTO C722P Connector pin Pin 3 Pin 4 ePTO C...

Page 710: ...rness 1 Resolve CAN communication problem 2 Troubleshoot specific error 3 Replace 12V fuse F11 4 Replace LV connector or harness per Service Manual No Contact fault messages appear on the HMI display...

Page 711: ...711 Troubleshooting Connector C101...

Page 712: ...e continuity measures from inside the fuse box Refer to connector investigation subtree Is fuse F11 on 12V fuse box C14 blown or intermittent Inspect fuse F11 on 12V fuse box C14 No Yes Were you able...

Page 713: ...nector pin C1 Pin 4 Pin 4 Pin L1 C15P_B ePTO C6 Connector pin Connector pin Pin 4 Pin M1 Pin 4 Pin J1 Pin 9 Pin L4 Pin 9 Pin M4 C15S C101 ground Connector pin Connector pin Pin 9 Pin 2 Contact Dana fo...

Page 714: ...nector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all connectors and wires between the...

Page 715: ...l problems which may cause a variety of different specific error messages to appear The technician should refer to these subtrees when instructed during troubleshooting of a specific error message Whe...

Page 716: ...ded Some onboard equipment such as the DCDC A C compressor and TMS monitor their HV connectors locally and alert the VCU via CAN if a connector is unplugged software HVIL In contrast the analog HVIL i...

Page 717: ...717 Troubleshooting Connector C22 Connector C40 Connector C73 Connector C91 Connector C202 Connector C300...

Page 718: ...718 Troubleshooting Connector C367P pin Connector C367S socket Connector C676 Connector C651 B Circuit73...

Page 719: ...being raised No Yes Install a jumper in connector C5 from pin 1 to pin 6 Turn ignition ON With a multimeter check for continuity between the following points Continuity Resistance is less than or equa...

Page 720: ...e all cables are connected properly Ensure all secondary locks are engaged Ensure no visual damage on the connectors and the harness Is the continuity restored after performing a wiggle test on all co...

Page 721: ...est points of the harness ends A3 12V fuse box C14 Ground Connector pin A3 GND strip1 Pin 6 GND strip1 C5 HV JB Ground Connector pin A Continued on next page Replace fuse F3 on 12V fuse box C14 Restar...

Page 722: ...g and ground Is there any evidence of a short circuit to the ground or the HV junction casing Yes Defective harness Replace harness No Continued from previous page Is there any evidence of a short cir...

Page 723: ...Continuity Resistance is less than or equal to 2ohms C5 HV JB C3 MCU Connector pin Connector pin Pin 6 Pin J Pin K Pin 1 C3 MCU C22 OBC Connector pin Connector pin Pin 33 Pin 5 C40P C367S Connector pi...

Page 724: ...less than or equal to 2ohms Pin 5 Pin 2 C367P C202 U5 Connector pin Connector pin Pin 6 Pin 34 C367S C40P Connector pin Connector pin Pin 8 Pin 6 C202 compressor C367P Connector pin Connector pin Pin...

Page 725: ...ted the technician should return to the original troubleshooting tree The vehicle has five CAN networks designated CAN A through CAN E which each connect a different set of devices The specific connec...

Page 726: ...CAN High pin CAN Low pin Diagnostics C410 1 12 VCU C651 A 17 1 A C compressor C71 2 1 SB C44 4 5 U8 C203 3 4 U5 C202 7 3 PNOVO C53 E4 F4 Termination resistor 1 C53 A A B Termination resistor 2 C649 A...

Page 727: ...727 Troubleshooting Connector C202 Connector C203 Connector C410 Connector C649 A Connector C651 A...

Page 728: ...CAN Low pin Diagnostics C410 2 11 VCU C651 A 18 2 HMI C650 A 8 5 TELEMETRY C416 6 8 Traction inverter C3 D C OBC C22 8 7 CHILLER C45 1 2 PNOVO C53 J4 K4 Termination resistor 1 C53 B A B Termination r...

Page 729: ...729 Troubleshooting Connector C53 B Connector C410 Connector C416 Connector C649 B Connector C650 A...

Page 730: ...730 Troubleshooting Connector C651 A...

Page 731: ...76 A3 A1 PRNDL P101 8 15 CND_FAN1 C82 5 10 CND_FAN2 C89 5 10 CN_LN C72 3 2 MPDM C10 6 12 OEM_RADAR OEM_RADAR H L PNOVO C53 G4 H4 Termination resistor 1 C53 C A B Termination resistor 2 C649 C A B Note...

Page 732: ...732 Troubleshooting Connector C72 Connector C82 Connector C89 Connector C410 Connector C649 C Connector C650 A...

Page 733: ...733 Troubleshooting Connector C651 A...

Page 734: ...Low pin Diagnostics C410 4 9 VCU C651 B 17 1 HMI C650 A 10 3 CLD_PMP C80 1 6 EPTO1 C6 A2 C2 EHPS_INV C34 6 7 EHPS_INV C34 3 4 DCDC C84 5 6 PNOVO C53 C4 D4 Termination resistor 1 C53 D A B Termination...

Page 735: ...735 Troubleshooting Connector C80 Connector C84 Connector C410 Connector C649 D Connector C650 A...

Page 736: ...736 Troubleshooting Connector C651 B Circuit73...

Page 737: ...nd Connectors CAN connector CAN High pin CAN Low pin Diagnostics C410 5 8 VCU C651 B 18 2 HMI C650 A 11 2 Termination resistor 1 C446 A B Termination resistor 2 C649 E A B Connector C410 Connector C44...

Page 738: ...738 Troubleshooting Connector C651 B Circuit73...

Page 739: ...corresponding to each CAN A Is the measured resistance less than 54 ohms Yes No B Inspect the connector terminals of all connectors on the suspect CAN network for traces of corrosion or improper conn...

Page 740: ...re resistance between CAN_H and CAN_L on the resistor pins and on the harness pins Is the problem resolved No Yes Defective harness Replace harness Complete No Is resistance across the resistor 108 13...

Page 741: ...sistor pins and on the harness pins Is resistance across the resistor pins 108 132 ohms Yes Is resistance across the harness pins 108 132 ohms No Replace termination resistor 2 No B Yes Replace termin...

Page 742: ...d measure the resistance between CAN_H and CAN_L on the harness side to identify anyparasitic resistance Is there a parasitic resistance found Yes No Defective harness Replace harness Contact Dana for...

Page 743: ...btree is used to troubleshoot problems with electrical connectors when requested during troubleshooting of a specific error message When the connector investigation subtree is completed the technician...

Page 744: ...ection Are any of the connector pins in the suspect device connector bent broken or recessed Yes Defectivedevice Replacedevice Is the initial code you weretroubleshooting stillbeing raised Yes No Comp...

Page 745: ...connector s Defective connector Replace the connector as described in the Wire Harness Connector Identification Location and Service Chart in the Service Manual Is there evidence of a continuity loss...

Page 746: ...d return to the original troubleshooting tree Cooling investigation Locate the coolant pump While the pump is running check the coolant level in the reservoir Is any unusual sound coming from the cool...

Page 747: ...Is any hose kinked pinched or loose Yes No Connect repair or replace the hose Refill coolant if necessary Is the coolant level low Yes No Refill coolant Check the cooling circuit for leaks Is there an...

Page 748: ...ubleshoot problems with the heating circuit when requested during troubleshooting of a specific error message When the heating circuit investigation subtree is completed the technician should return t...

Page 749: ...Check the heating circuit for leaks Is there any leak in the heating circuit Yes No Repair the leak and refill fluid Heating circuit investigation If the heater was used recently wait for components t...

Page 750: ...ce to activate the heater pump Does the heater pump run when requested No Yes Does fluid flow out of the reservoir when the pump is running No Disconnect hose from pump outlet Pinch off hose Is the pu...

Page 751: ...at a time and check for obstructions Reconnect the hose to the pump outlet Refill fluid as needed Is the heating circuit obstructed No Yes Clear obstruction reconnect hoses and refill fluid as needed...

Page 752: ...pump Disconnect connector C651 B from VCU Remove fuse F15 in order to take continuity measures from inside the fuse box Refer to the connector investigation subtree No A B Continued on next page WARNI...

Page 753: ...51 B Connector pin Is there any evidence of continuity loss Defective harness Replace harness Yes No Is there any problem with the connector integrity Defective connector Replace the connector as desc...

Page 754: ...vice Manual B Refer to the connector investigation subtree With a multimeter check for short circuit between the following points LV short Resistance measurement is less than 100k ohms Inspect all con...

Page 755: ...ircuit within the harness Defective harness Replace harness Yes No Defective heater pump Replace heater pump Complete Did fuse F15 blow again during a test drive No Yes Replace fuse F15 on 12V fuse bo...

Page 756: ...original troubleshooting tree The relays on the vehicle and their pins are listed in the table below Relay number Pin A Pin B Pin C Coil Pin A Coil Pin B K001 4 3 5 1 2 K002 4 3 5 1 2 K003 4 3 5 1 2 K...

Page 757: ...measure the resistance between the following pins of the relay Relay Connector Pin B Pin A Relay Connector Relay Connector Pin B Pin C Relay Connector The multimeter should read a resistance around 0...

Page 758: ...lay No Yes Defective relay Replace relay With a multimeter measure the resistance between the following pins of the relay Relay Connector Pin B Pin C Relay Connector Relay Connector Pin B Pin A Relay...

Page 759: ...S Box SB Charging system Charge controller CCU FSVCU Safety controller PNOVO Charge controller FSVCU supervisory controller Charge inlet Inlet OBC OBC OBC Propulsion system Traction inverter MCU Trac...

Page 760: ...D_FAN_2 Radiator Fan 02 Cabin Heater HTR Cabin Heater Heater pump HT_PMP HVAC water pump VCU HMI system HMI HMI VCU VCU Parker MC43 Cooling system Powertrain coolant pump CLD_PMP Telemetry system Tele...

Page 761: ...ce assistance call 1 877 777 5360 or visit our website at www Dana com AllapplicationsmustbeapprovedbytheApplicationEngineeringDepartment Specificationsand ordesignaresubjecttochangewithoutnoticeorobl...

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