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DANA SPICER TM4 SUMO HP HV Powertrain, Troubleshooting Manual

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DANA SPICER TM4 SUMO HP HV Powertrain Troubleshooting Manual Download Page 181

 

 

 

181 

Appendix 

Appendix 2: Table of Troubleshooting Trees 

The following table of the SysFile ID gives the in formation of the diagnostic type, the code description and the 
related Troubleshooting Tree . 
 

Troubleshooting 
Tree  

SysFile IDs  Causes (numbered in order of likely occurrence) 

01 

0x0000 

 

1. 

Wrong shutdown sequence. Auxiliary vehicle battery (Vaux) (12V or 
24V) powered OFF before the MCU “ReadyToPowerOff” CAN status 
on a shutdown sequence. 

2. 

Manual SysFile reset by an advance user. 

3. 

Defective MCU. 

02 

 

0x000A 
0x1300 
0x4209 

1. 

Wrong previous shutdown sequence. Auxiliary vehicle battery (Vaux 
12V or 24V) powered OFF before the MCU “ReadyToPowerOff” CAN 
status on a shutdown sequence. 

2. 

Defective MCU. 

03 

0x0313 

1. 

DCDC not regulating auxiliary DC voltage correctly. 

2. 

High auxiliary load being activated causing voltage drop. 

3. 

The auxiliary vehicle battery does not operate correctly. 

4. 

Intermittent or bad Vaux connection at the MCU. 

5. 

Vaux Fuse burnt. 

6. 

Defective MCU. 

04 

0x0314 

1. 

DCDC system not regulating auxiliary DC voltage correctly. 

2. 

Intermittent contact to the auxiliary vehicle battery that can cause 
voltage spikes due to load dump of the DCDC system. 

3. 

The auxiliary vehicle battery is not working properly. 

4. 

The MCU is defective. 

05 

0x0315 
0x0316 
0x0321 
0x0322 
0x0323 
0x0324 
0x0325 
0x0326 
0x3109 
0x3400 
0x3401 
0x3402 
0x3403 
0x3404 
0x3406 
0x3408 
0x3500 
0x4801 
0x4B00 
0x4B01 
0X4B02 
0x4B03 

1. 

 Some foreign material within the MCU or motor connector short 
some signals. 

2. 

MCU or motor connector pin is bent or broken. 

3. 

Motor sensor cable defective. 

4. 

Defective motor. 

5. 

Defective MCU. 

Summary of Contents for SPICER TM4 SUMO HP HV Powertrain

Page 1: ...1 Dana TM4 SUMO HP HV Powertrain Troubleshooting Guide SMTS 0603 March 2022 ...

Page 2: ...ures creates a high risk of personal injury to the servicing technician CAUTION Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the service of this unit This symbo...

Page 3: ...ase of damaged casing or suspected product malfunction contact Dana TM4 Customer Service Use only recommended points to lift and secure the MCU When using straps to lift the MCU ensure they do not touch or put pressure on any part of the product exterior surface connectors and or cables Do not attach the motor to the MCU using a shared support or bracket Do not apply any external load to the casin...

Page 4: ...the cooling agent breathing in high concentrations of ethylene glycol can cause nausea In case of contact with eyes and skin rinse with water and consult a doctor In case of ingestion seek medical help immediately The cooling agent is under pressure when heated removing the cap when the coolant is hot can cause serious burns and or other injuries Wait until the coolant reaches an ambient temperatu...

Page 5: ...iation and Definition 33 Troubleshooting Tree s Tables Details 33 Troubleshooting Tree Legends 34 TT01 35 TT02 37 TT03 39 TT04 45 TT05 50 TT06 56 TT07 58 TT08 60 TT09 65 TT10 70 TT11 74 TT12 78 TT13 81 83 TT14 84 TT15 86 TT16 88 TT17 90 TT18 92 TT19 94 TT20 98 TT21 104 TT22 106 TT23 108 TT24 110 TT25 112 TT26 114 TT27 116 TT28 118 120 TT29 121 TT30 123 TT31 126 TT32 133 TT33 140 TT34 144 TT35 149 ...

Page 6: ...tal Signal Processor ECU Electronic Control Unit EMF Electro Motive Force ESD Electrostatic Discharge EV Electrical Vehicle GΩ Giga Ω unit GDD TM4 ODIN Gathered Diagnostic Data sub program h hour unit HVIL Hazardous Voltage Interlock Loop HS High Side kW kilo Watt unit kΩ Kilo Ω unit mA Milliampere unit L Liter unit L h Liter per hour unit MΩ Mega Ω unit MCU Motor Control Unit Nm Newton meter unit...

Page 7: ...g and stopping the system o Applying a mechanical torque o Safely shutting down the system o Verifying operational status Hazardous Voltage Interlock Loop HVIL The Hazardous Voltage Interlock Loop HVIL internal loop is closed resulting in a short circuit between its two input pins The HVIL signal is used to open the high voltage battery contactor when its internal loop is opened during product mai...

Page 8: ...Mishandling of this product may damage the product and or cause injury or death Do not attempt to open or repair this product In case of damaged casing or suspected product malfunction contact Dana TM4 Use only recommended points to lift and secure the system When manipulating and or installing this product you must NOT Modify any part of the MCU Apply any external load to the casing of the MCU Ap...

Page 9: ...9 General Information Dana TM4 Motor and MCU Components Example Dana TM4 Motor Dana TM4 MCU ...

Page 10: ... is composed of the MCU and motor Refer to the System Specification guide for your system The table below is an example The MCU has the following connectors Communication connector Grounding Point DC connectors Phase Connectors Motor Sensor Connectors Coolant IN OUT connectors ...

Page 11: ..._OUT High side Output 20 16 Generic high side output 200mA 8 Vaux Power 20 16 Positive power wire of the MCU Must be connected to the auxiliary battery using fuse type 9 CAN1L Communication 20 16 Low level of differential signal CAN1 10 CAN2H Communication 20 16 High level of differential signal CAN2 11 5V SENSOR Analog supply 20 16 12 PWM2_OUT Low side output 20 16 Generic Low side Output 1A can ...

Page 12: ...ame point or the same vehicle chassis frame side Conductive grease should be used on each of the contact points to ensure reliable and durable grounding connections The resistance between the grounding points and the chassis must be tested each time the connection is impacted The resistance must be less than 0 1 Ω MCU and motor grounding point locations product type example Motor Phase Connectors ...

Page 13: ...ut mapping from Dana TM4 MCU to TM4 motor MCU pin out Signal name TM4 Motor pin out 1 Temperature C F3 9 Temperature C F2 16 Temperature B A3 2 Temperature B A2 10 Temperature A A4 17 Temperature A B4 3 R1_OUT A1 11 R2_OUT B1 18 COS S1 C1 4 COS S3 D1 12 SIN S2 E1 19 SIN S4 F1 5 HVIL_TO_MOTOR F4 13 1 Wire OUT C2 20 1 Wire GROUND C3 6 HVIL_FROM_MOTOR E4 N C Chassis N C Typical MCU sensor connector T...

Page 14: ...14 General Information Motor connector head Identification Dana TM4 MCU A3 Dana TM4 Motor ...

Page 15: ...e MCU The negative terminal of the battery must be connected to the frame of the vehicle chassis Auxiliary Battery Fuse To protect the system against short circuit a fuse is connected in series with the positive terminal of the auxiliary battery Note Refer to the Installation guide for further details ...

Page 16: ... develop by ex TM4 E Motor type ex MC370 F Motor size ex 300 G Software family letter ex D H Software version Major minor delivery and change list ex V5 4 4 113772 As an example here is a typical software package file name MCU_INVHP2HV_0206_TM4_MC370_300_D_v5_4_4_113772_Pkg exe File Name Description Embedded Software Package Executable MCU_INV ABCDEFGH Pkg exe See note on software PACKAGE naming E...

Page 17: ...to the MCU and the motor to dissipate the excess heat The motor and the MCU are linked to the cooling system by a fan pump coolant tank and radiator configuration There are two possible configurations for the cooling system the parallel configuration and serial configuration Parallel Configuration Serial Configuration MCU example with coolant inlet and outlet indications Motor example with coolant...

Page 18: ...active corrosion inhibitors The ethylene glycol must be diluted with de ionized water not distilled water The dilution ratio must be 60 ethylene glycol to 40 de ionized water minimally 50 ethylene glycol to 50 de ionized water Two different types of coolant should not be mixed As the cooling unit cooling hose and cooling agent are not supplied by Dana TM4 the vehicle integrator has full responsibi...

Page 19: ...t cables from damage due to gravel or other environmental factors Allow for enough room for air circulation clearance space for movement and access to cables for maintenance etc When securing cables Ensure that each cable is appropriately supported connector strain relief High voltage cables secured no more than 10 cm from the connectors Low voltage cables secured no more than 30 cm from the conne...

Page 20: ... SUMO Fuse and DC Cable Selection published on the Knowledge base section of the Dana TM4 extranet site for proper fuse selection High voltage battery pre charge circuit The system requires the protection of a pre charge circuit without which the system start up sequence will fail and the MCU may be permanently damaged This pre charge mechanism will protect the system from component stress during ...

Page 21: ...ith DB9 connector VMU interface connector Vaux input Ignition enable CAN termination resistor PC With TM4 ODIN installed USB port DB9 connector 2 CAN L 7 CAN H CAN GND Grounding straps Cooling source pump and radiator Cooling in Cooling out Cooling in Cooling out Cooling in Cooling out Vehicle chassis USB to CAN interface connector NC CAN interface channel X Phase cables Motor sensor harness Legen...

Page 22: ...ows 7 8 with limited access Software extraction zip 7zip WinRar Note Windows XP and lower version are no longer supported Any of the supported CAN interfaces below o Kvaser USB cable interfaces o PEAK System PCAN USB PCAN PCIe and PCAN USB Pro interfaces o Vector Vector XL Interface family for example CANcaseXL CANboardXL CANcardXLe and CANcardLe and the VN16XX series are all supported by TM4 ODIN...

Page 23: ...used to check Continuity Effective Ground connection Broken wires Open circuits Shorted circuits Incorrect voltage level high voltage battery or Vaux MegΩmeter This device is used to measure the insulation of high voltage equipment or installation that may present a safety hazard in the event of a fault The measurement is performed by generating a high DC voltage with a specific current magnitude ...

Page 24: ...e CAN interface to the CAN port of the Dana TM4 product Then connect the CAN interface to your computer You may need an adaptor depending on the CAN interface CAN box used The specific characteristics for the implementation of the CAN buses are described in the technical documentation for the Dana TM4 product you are using Note CAN protocol supports parallel connections It is possible to use a CAN...

Page 25: ...the GDD files 1 Power on the unit with the appropriate Auxiliary Vehicle Battery Vaux supply 2 Turn the ignition ON for the MCU to be enabled 3 Open Odin Server 1 and establish connection to the MCU The Process description is in Appendix 4 Retrieve GDD Files and User Parameters 4 Make sure that at the bottom left of the Odin screen Device Connected is displayed in green text 5 In Odin Server 1 in ...

Page 26: ...nu select GDD or click the icon in the tool bar Note GDD with CAN trace is also available and can be invoked if a CAN trace is required 8 Click on and browse to the folder where the zip file is created 9 Click on the Start button to begin the process Note If GDD with CAN trace was selected a new window opens to begin the CAN trace recording 10 On the new window click on the Start button CAN trace ...

Page 27: ... the Abort button on the second window to stop the process Once the data has been gathered the Email Data button on the first window becomes available It generates an email with the zip Cancel can be selected to avoid sending an email with the data right away SysFile ID File 1 After retrieving the GDD zip file extract the file SysFile csv ...

Page 28: ...e SysFile ID Event Description Brief description of the SysFile ID Event Data This data gives precision about the cause of event Time Amount of time after the unit power up the Event Code occurs DTC ID Not used Proposed Actions Not used 1 2 3 4 5 6 7 1 2 3 4 5 6 7 ...

Page 29: ...ing Tree that refer to a specific diagnostic tree Table of SysFile ID The following table of the SysFile ID provides the information of the diagnostic type the code description and the related Troubleshooting Tree see the section Appendix 1 Table of SysFile ID in the Appendix section Table of Troubleshooting Tree The table of Troubleshooting Tree provides the information of the SysFile ID Troubles...

Page 30: ...0x4000 12 0x032E 9 0x3105 18 0x4001 36 0x032F 10 0x3109 5 0x4002 36 0x0330 10 0x310A 19 0x4003 36 0x0331 11 0x310B 20 0x4004 36 0x0332 11 0x310C 20 0x4005 36 0x0501 12 0x310D 21 0x4006 36 0x0502 12 0x310E 21 0x4007 36 0x0503 12 0x310F 22 0x4008 36 0x0504 12 0x3110 22 0x4009 36 0x0505 12 0x3111 12 0x400A 36 0x0506 39 0x3112 23 0x400B 36 0x0507 39 0x3113 27 0x400C 36 0x0508 39 0x3200 28 0x400D 36 0x...

Page 31: ...0x4111 36 0x4112 36 0x4121 37 0x4122 37 0x4123 37 0x4124 37 0x4125 37 0x412D 37 0x4209 2 0x4703 37 0x4801 5 0x4B00 5 0x4B01 5 0x4B02 5 0x4B03 5 0x4F01 36 0x4F02 36 0x4F03 36 0x4F04 36 0x4F05 36 0x4F06 36 0x4F07 36 0x4F08 36 0x4F09 36 0x4F0B 36 0x4F0D 36 0x4F0E 36 0x4F0F 36 0x4F10 36 0x4F11 36 0x4F12 36 0x4F21 36 0x4F22 36 0x4F23 36 0x4F24 36 0x4F25 36 0x4F2D 36 ...

Page 32: ...rror message only to have it display again when the fault condition reoccurs To make sure an issue is fixed be sure to run the system through the same operating modes that caused the issue and verify that the service code does not reappear Electrical faults are often connection problems The most likely cause of electrical faults will be damaged wires or connections As a first step in troubleshooti...

Page 33: ...s used in multiple Troubleshooting Tree s TT SysFile ID Service Codes SysFile IDs SysFile IDs are shown by software ODIN They describe an error warning or information message related to the unit System Mode SysFile ID Condition Possible Causes Functional state of the unit when the Condition dysfunctional event occurs List of the Service Code SysFile ID related to the Troubleshooting Tree TT Detail...

Page 34: ... related to the unit involved Sub tree Indicates a sub tree present in this document Process Actions Indicates any process or action to do Assistance Process Indicates a process we describe an assistance action Ex Call Dana TM4 for help Question Decision Choice Indicates a decision point between two or more paths in the tree Document Indicates the document to refer for a dedicated action ...

Page 35: ...ile gets written in the unit EEPROM memory upon a shutdown sequence If the Vaux power 12 V or 24 V is removed before the MCU is in ReadyToPowerOff state via CAN the SysFile section could possibly get corrupted and will be cleared on the next power ON Note Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning consider...

Page 36: ...36 Service Codes ...

Page 37: ...r upon writing while power Vaux is removed Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Tr...

Page 38: ...38 Service Codes ...

Page 39: ...user may require specialized equipment to diagnose this fault This can be also that the Vaux Fuse is burnt The MCU itself may be defective Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment...

Page 40: ...n VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 41: ...41 Service Codes Connector type 2 pinout Connector type 1 pinout ...

Page 42: ...ystem causing high load on the network With a mutilmeter measure the voltage between the following pins in the VMU ECU interface harness connector Interface connector Type 1 Connector pin Connector pin Pin E or F Vaux Pin L or M Vaux Interface Connector Type 2 Connector pin Connector pin Pin 8 or 15 Vaux Pin 22 or 23 Vaux With a mutilmeter measure the resistance between the following pins in the V...

Page 43: ...ct VMU interface connector on the MCU Does the same SysFile ID occur again Yes Defective MCU Replace MCU Complete No Turn ON ignition Connect to the MCU with ODIN tool and check the SysFile Switch ON the auxiliary batteries switch A Replace fuse No Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations ...

Page 44: ...solve problems Refer to the Verify Connector Integrity Subtree STT01 Is there any evidence of an integrity loss on the VMU ECU interface MCU connector Yes Defective MCU Replace MCU No Complete Inspect the VMU ECU interface connector Switch OFF the auxiliary batteries switch Switch OFF the auxiliary batteries switch B Refer to the Dana TM4 Product installation guide for more details on installation...

Page 45: ... may be defective Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sectio...

Page 46: ...VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 47: ...47 Service Codes Connector type 2 pinout Connector type 1 pinout ...

Page 48: ...stigate the 12V 24 V board net for Defective DCDC system Defective auxiliary batteries Is there evidence DCDC or auxiliary batteries are causing the over voltage Yes No Reconnect VMU interface connector on the MCU Switch ON the auxiliary batteries switch Does the same SysFile ID occur again Yes Defective MCU Replace MCU Complete No Refer to the system troubleshooting to solve problems Connect to t...

Page 49: ...batteries to VMU ECU interface harness connector Yes No Refer to the system troubleshooting to solve problems Reconnect VMU interface connector on the MCU Make sure ignition is ON Does the same SysFile ID occur again Yes Defective MCU Replace MCU Complete No Inspect the VMU ECU interface connector Connect to the MCU with ODIN tool and check the SysFile A Switch OFF the auxiliary batteries switch S...

Page 50: ...the motor is not a Dana TM4 motor then the measurements may be different In that case refer to your motor specification Note Refer to the TM4 motor installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and...

Page 51: ...51 Service Codes Motor internal resistance measurement table ...

Page 52: ...52 Service Codes Connector Head Identification TM4 Motor connector Type 1 TM4 Motor connector Type 2 ...

Page 53: ...53 Service Codes ...

Page 54: ...54 Service Codes ...

Page 55: ...55 Service Codes ...

Page 56: ...cuited through the MCU power modules the battery current will temporarily exceed the threshold limit upon failure and raise this SysFile ID error This error can therefore be ignored following the 0x3113 warning TT27 Back EMF Motor reduction mechanism activated phases are short circuited Other error s must be investigated To correctly diagnose the faulty system connect the Diagnostic Tool see Diagn...

Page 57: ...57 Service Codes ...

Page 58: ...de for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Refe...

Page 59: ... motor Yes Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning considerations Turn ignition OFF and ON twice Connect to the MCU with ODIN to check the SysFile Ensure that the motor sensor cable is well connected from the MCU to the motor with both connectors locking mechanism engaged MCU and motor ...

Page 60: ...opening the HVIL loop from the HVIL input of the MCU To fix this fault refer to the troubleshooting guide of the other system 3 The connectors that connect the HVIL circuit to the MCU are somehow defective In this case the VMU ECU connectors must be disconnected from the MCU and repaired 4 The MCU itself is defective It should be disconnected and replaced Note Refer to the TM4 Product installation...

Page 61: ...61 Service Codes Connector Head Identification VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 Connector Front Type 2 Wire Insertion Side Back Type 2 ...

Page 62: ...62 Service Codes Connector type 2 pinout ...

Page 63: ...63 Service Codes ...

Page 64: ...64 Service Codes ...

Page 65: ... opening the HVIL loop from the HVIL output of the MCU To fix this fault refer to the troubleshooting guide of the other system 3 The connectors that connect the HVIL circuit to the MCU are somehow defective In this case the system must be turned OFF and the connectors must be repaired 4 The MCU itself is defective and must be replaced Note Refer to the TM4 Product installation guide for more deta...

Page 66: ...66 Service Codes Connector Head Identification VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 Connector Front Type 2 Wire Insertion Side Back Type 2 ...

Page 67: ...67 Service Codes Connector type 2 pinout ...

Page 68: ...68 Service Codes ...

Page 69: ...69 Service Codes ...

Page 70: ...t be turned OFF and then the cables must be locked by the locking mechanism engaged on both sides MCU and motor 4 The motor is defective 5 The MCU is defective Note Refer to the TM4 Product Operation and maintenance guide for more details Note Refer to the TM4 MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to ...

Page 71: ...71 Service Codes ...

Page 72: ...72 Service Codes ...

Page 73: ...73 Service Codes ...

Page 74: ...ters to set them according to the needs and the limits set by the Operations and Maintenance Guide 2 There is a problem with the HVIL power source that is connected to the HVIL line This problem is external to the Motor Control Unit MCU refer to HVIL source Troubleshooting Guide 3 The MCU is defective The system must be turned OFF and the MCU removed and replaced Note Refer to the TM4 Product Oper...

Page 75: ...VMU ECU Interface Type 2 VMU ECU interface harness Plug Pinout Type 2 VMU ECU Interface Type 1 VMU ECU interface harness Plug Pinout Type1 Connector Front Type 2 Wire Insertion Side Back Type 2 Connector Front Type 1 Wire Insertion Side Back Type 1 ...

Page 76: ...76 Service Codes ...

Page 77: ...77 Service Codes ...

Page 78: ...nd Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT12 call the following process Appendix 6 Update Software System Mode Referred by SysFile ID Condition Possible Causes Initialisation power up 0x0312 0x0501 0x0502 0x0503 0x0504 0x0505 0x050E 0x050F 0x051B 0x051C 0x1207 0x3111 0x3300 0x3304 0x330A 0x330C 0x330D 0x4000 Error detected at initialization...

Page 79: ...79 Service Codes ...

Page 80: ...o use the proper motor part number that is compatible with your system Is the MCU software version on your note matching corresponding to the one found under the DANA TM4 extranet folders Yes Download the official software version from the extranet site and execute the file on the PC where ODIN is installed No Click the server icon located just below the File ODIN menu twice once to disconnect and...

Page 81: ...motor sensor connection between the MCU and the motor To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Initia...

Page 82: ...r and on the MCU Turn ignition OFF Wait for 10 minutes before taking any further action Disconnect all the connectors located on the motor Turn ignition ON Yes Yes Open ODIN and check the status bar to see which software version is running No Turn ignition ON Connect to the Dana TM4 extranet Access to your system and open all MCU MOTOR and SOFTWARE subfolders under your system Connect to the MCU w...

Page 83: ...he MCU and the motor Does the same SysFile ID occur again No Connect the motor sensor cable properly between the MCU and the motor Refer to the TM4 Product installation guides No Turn ignition ON Connect to the MCU with ODIN to check the SysFile Switch ON the auxiliary batteries switch A B Yes Yes ...

Page 84: ...Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the troubleshooting procedure tree below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT14 call the following process Appendix 6 Update Software System Mode Referred by SysFile ID Condition Possible Causes Initialisation power up 0x2209 0x...

Page 85: ...85 Service Codes ...

Page 86: ... installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics...

Page 87: ...87 Service Codes ...

Page 88: ...he motor installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system dia...

Page 89: ...89 Service Codes ...

Page 90: ...em connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT17 call the following process Appendix 6 Update Software System Mode Referred by SysFile ID Condition Possible Causes Initialisation pow...

Page 91: ...91 Service Codes ...

Page 92: ... connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Operational 0x3100 0x3101 0x3102 0x3103 0x3104 0x3105 Inconsistency between the internal control lo...

Page 93: ...voltage level Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning considerations Connect to the MCU with ODIN to check the SysFile Turn ignition ON Did the same SysFile ID occur along with any of the SysFile ID s 0x3200 to 0x3208 in the same session under the Same Info System power up No No Yes Yes Complete Refer t...

Page 94: ...charger Refer to the related Service Manual of these listed systems Note Refer to the Battery Pack Troubleshooting Guide to get the pinout of the related Battery Pack connector to perform the correct continuity check To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See...

Page 95: ...or visible damage With Ohmmeter check electrical continuity between the MCU and high voltage battery pack along the cables in all battery chain PDU contactor DC IN Battery Pack cable connectors cable connectors MCU DC MCU DC Was the main contactor opened before the MCU was commanded to shutdown during system operation No Note The SysFile ID was raised by the MCU because the High voltage main conta...

Page 96: ...e connectors to the MCU Check the cabling for continuity between the MCU and motor grounding dedicated points and vehicle chassis grounding point s Inspect grounding straps for visible damage With Ohmmeter check electrical continuity between the MCU and motor bodies to vehicle chassis grounding point s Conductive grease used on all grounding contact points MCU motor and vehicle chassis MCU Vehicle...

Page 97: ...attery Management System or Battery Interface Module Defective battery contactor causing intermittent contact Defective controller VMU ECU Lower than normal High Voltage battery level Defective Power Distribution Unit or connection between MCU and Power Distribution Unit Defective battery charger Does the same SysFile ID occur again Complete No B Refer to the Dana TM4 product installation guide fo...

Page 98: ...fluctuate due to resonances on the DC line beyond the high voltage detection point Note Refer to the MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the TM4 Product installation guides for more details on grounding MCU and motor To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnost...

Page 99: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 100: ...again Perform a road test with ODIN connected to the MCU Yes No Yes Complete Yes Turn ignition ON Does the text BlackBox info available appears in the status bar at the bottom of the window Connect to the MCU with ODIN and check the status bar Access the BlackBox data under Diagnostic BlackBox View BlackBox Check the Vbat waveform No A B D Turn the vehicle ignition to OFF Yes Ensure that the vehic...

Page 101: ... taking any further action Yes A Switch OFF the auxiliary batteries switch Ensure all High Voltage Electrical sources are switched OFF D Check the cabling for continuity between the MCU and motor grounding dedicated points and vehicle chassis grounding point s Inspect grounding straps for visible damage With Ohmmeter check electrical continuity between the MCU and motor bodies to vehicle chassis g...

Page 102: ...ts for hot spots on the MCU and the cables Defective MCU Replace MCU Investigate possible contactor intermittence or any contacts in the battery chain from contactor to MCU that could be intermittent B D No D Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning considerations Reconnect the DC High Voltage connection...

Page 103: ... comply to the product installation guides requirements No Yes Yes Investigate the vehicle for external root causes that might be causing the SysFile ID to be raised Another defective system on the DC bus causing electrical overloads Defective Battery Management System or Battery Interface Module Defective battery contactor causing intermittent contact Higher than normal High Voltage battery level...

Page 104: ...h does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual Note The wrong phase cable crimping on one or more of the phase lugs Replace the cable To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety...

Page 105: ...105 Service Codes ...

Page 106: ...ture must be replaced Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnin...

Page 107: ...107 Service Codes ...

Page 108: ...badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual Note The DC cable crimping on one or more of the DC connection lug or POC Replace the cable To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure b...

Page 109: ...109 Service Codes ...

Page 110: ...anual Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troublesh...

Page 111: ...111 Service Codes ...

Page 112: ... temperature is too high to cool the motor The system must turn Ignition off and the coolant mixture must be replaced Refer to the cooling system Service Manual Note The mixture of the cooling liquid was done badly which does not let the coolant cool the motor Replace the mixture of cooling liquid Refer to the cooling system Service Manual To correctly diagnose the faulty system connect the Diagno...

Page 113: ...113 Service Codes ...

Page 114: ...stic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT26 call the following process Appendix 6 Update Software System Mode Referred by SysFile ID Condition Possible Causes Operational 0x0317 0x0318 0x1001 0x1002...

Page 115: ...115 Service Codes ...

Page 116: ...h voltage maximum limit until the motor speed is reduced under the unsafe speed At the time the motor phases are short circuited it is normal that the phase currents and potentially the input DC current will temporarily exceed the limits and raise these errors type Other error s must be investigated Note Refer to the Application note High Speed fault Management Document To correctly diagnose the f...

Page 117: ...117 Service Codes ...

Page 118: ...stem while the motor speed is beyond the unsafe speed the motor phases will be short circuited by the control to maintain DC bus under the high voltage limit until the motor speed is reduced below the unsafe speed At the time the motor phases are short circuited it is normal that the phase currents and potentially the input DC current will temporarily exceed the limits and raise these errors type ...

Page 119: ...e VMU ECU interface connector Is there any evidence of an integrity loss on the MCU connector Disconnect the VMU interface connector of the MCU Was the Warning Motor Control Inverter 0x00 to 08 raised under the same Info System power up as any listed phase current reached the maximum error s No Was the 0x050B and or 0x050C error raised under the same Info System power up as Warning Back EMF Motor ...

Page 120: ...installation procedure including safety warning considerations Complete Reconnect the VMU ECU interface connector to the MCU Turn ignition ON Connect to the MCU with ODIN and check the SysFile Does the same SysFile ID occur again Yes No Defective MCU Replace MCU Switch ON the auxiliary batteries switch A B ...

Page 121: ...er to the MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on syste...

Page 122: ...122 Service Codes ...

Page 123: ...fluxing current at high speed and this error will be raised Note Refer to the TM4 ODIN technical guide for more information Note Refer to the TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptio...

Page 124: ...cooling circuit integrity subtree STT02 Connect to the MCU with ODIN Open the Userinterface odn4 workspace located under the Package Files Workspaces ODIN menu and select the CAN interface tab Then open the McuThermal1 folder refer to picture example Drive the vehicle on the road while looking at the DriveCoolingFlowRequest and MotorCoolingFlowRequest values in ODIN Refer to the TM4 ODIN technical...

Page 125: ...125 Service Codes References ...

Page 126: ...e next page The MCU itself may be defective Note Refer to the Dana TM4 product installation guide including safety warning considerations and operation and maintenance manual for more details on the phase cables configurations and parameter setting To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubles...

Page 127: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 128: ...se connectors or connection points on the MCU and the motor Access the BlackBox data under Diagnostic BlackBox View BlackBox Check the Motor Resolver Angle Waveform A Wait for 10 minutes before taking any further action Turn ignition ON Connect to the MCU with ODIN Yes No Are there phase cables damaged Phase lugs have to be properly screwed and ensure good contact POC connectors have to be well in...

Page 129: ...bles If routed near any of those cables it might disturb the signal and create DC consumption variations that could affect the control and create this error type to be raised by the system Defective MCU Replace MCU Wait for 10 minutes before taking any further action Yes No D The motor resolver cable need to be routed away from high voltage cables Refer to integrator installation guide for appropr...

Page 130: ...nnector from the motor E Disconnect the motor sensor connector at the MCU side Refer to the Verify Connector Integrity Subtree STT01 Yes Is there any evidence of an integrity loss on the motor sensor interface connector D Yes No Investigate the connector integrity of the motor sensor interface connector on the MCU Investigate the connector integrity of the motor sensor interface connector on the m...

Page 131: ...oup 3 Phase A3 B3 C3 phases motor type Defective motor Replace motor No C Close the motor phase panel or blanket or reconnect the motor phase POC Yes Complete Perform a road test to check further error occurrences of the original error code Wait for 10 minutes before taking any further action Yes Turn ignition ON E Connect to the MCU with ODIN and check the SysFile Does the same SysFile ID occur a...

Page 132: ...or bodies to vehicle chassis grounding point s Conductive grease used on all grounding contact points MCU motor and vehicle chassis MCU Vehicle chassis MCU dedicated grounding point Vehicle chassis grounding point Motor dedicated grounding point Vehicle chassis grounding point Motor Vehicle chassis To To Is any of the measured resistance over 0 1 Defective grounding strap s or resistive connection...

Page 133: ...entially trigger the fault Software upgrade might solve the issue providing more filtering to the detection Note Refer to the Dana TM4 Product installation guides for more details on installation and deinstallation procedure including safety warning considerations Note Refer to the TM4 Product Interface drawing for more details on torque requirement Note Phase cables Ensure that the manufacturer o...

Page 134: ...s under your system No Is the software package flashed to the MCU is the up to date software as published on the Dana TM4 extranet site for your system Download and execute the software package from the Dana TM4 extranet site Turn ignition OFF Flash the up to date software package to the MCU Refer to the Appendix section Update Software Turn ignition ON No Perform a road test to check further occu...

Page 135: ...els or blankets MCU and or motor Inspect the phase connection points for any foreign material or phase cable shield that would be too close to the phase connection point s No Yes Is one or more phase cables between MCU and motor visibly damaged Replace damaged phase cables Turn ignition ON Does the same SysFile ID occur again Complete No Yes Yes No B C Connect to the MCU with ODIN to check the Sys...

Page 136: ...Can the identified connection point s lug and DC contact point be cleaned without compromising contact integrity No D No Clean the DC lugs and contact points with isopropyl alcohol using a brush Turn ignition ON Complete Yes Perform a road test to check further occurrences of the original SysFile ID Yes Wait for 10 minutes before taking any further action Defective MCU Replace MCU Ensure all High ...

Page 137: ...at would be caused by a loose phase mounting screw Wait for 10 minutes before taking any further action Does the same SysFile ID occur again Is there any foreign material or phase cable shield found near any of the phase connection points Reinstall the phase panels or blankets Ensure all High Voltage Electrical sources are switched OFF Switch OFF the auxiliary batteries switch Switch ON the auxili...

Page 138: ...mmeter that can inject a voltage of 1000 V while measuring measure between the phase cable lug to the phase cable shield cable gland metallic part of all the phase cables to identify the faulty cable s Is the measurement of any phase cable under 10 Mohm Change the faulty phase cable accordingly Yes No Contact Dana TM4 support for assistance Yes Access the DC connection points by either removing th...

Page 139: ...ame SysFile ID occur again No D Yes Turn ignition ON Perform a road test to check further occurrences of the original SysFile ID Complete Connect to the MCU with ODIN to check the SysFile Switch ON the auxiliary batteries switch E ...

Page 140: ...m speed fault will therefore trigger when the speed forward or backward reach the parameter setting forward or backward Note on maximum speed reached It is possible to reach maximum speed limit regardless of the speed derating in the case the vehicle is going down a downhill slope and the mechanical brake are not used to slow down the vehicle In this case it is imperative that the driver act on th...

Page 141: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 142: ... UserInterface workspace file under Packages File Workspaces in ODIN menu Verify the Motor SpdFwdMax and Motor SpdBwdMax parameters Does the same SysFile ID is reported in the SysFile on subsequent Info System power up No The motor speed went over the speed parameter limit forward or backward direction Yes Yes Access the BlackBox data by selecting the Diagnostic BlackBox View BlackBox Check the mo...

Page 143: ...erify Connector Integrity subtree STT01 Is there any evidence of an integrity loss on the motor sensor connector on the motor No Defective Motor Replace Motor Yes No Defective MCU Replace MCU Yes Ensure all High Voltage Electrical sources are switched OFF Switch OFF the auxiliary batteries switch Refer to the Dana TM4 product installation guide for more details on installation and deinstallation p...

Page 144: ...tects a phase current mismatch between the 3 phases systems it will raise this error by stopping the system to be in operation right away preventing another motor phase to burn internally To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the procedure of Troubleshooting Tree below See Safety Warnings and Troub...

Page 145: ...145 Service Codes ...

Page 146: ...146 Service Codes ...

Page 147: ...147 Service Codes ...

Page 148: ...148 Service Codes ...

Page 149: ... will put the MCU in error To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the procedure of Troubleshooting Tree below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The TT35 call the following process Appendix 6 Update Software System Mode ...

Page 150: ...150 Service Codes ...

Page 151: ...and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Operational 0x4001 0x4002 0x4003 0x4004 0x4005 0x4006 0x4007 0x4008 0x4009 0x400A 0x400B 0x400C 0x400D 0x400E 0x400F 0x4010 0x4011 0x4018 0x4019 0x401A 0x401B 0x401C 0x401E 0x4020 0x4021 0x4022 0x4023 0x4101 0x4102 0x4103 0x4104 0x4105 0x4106 0x4107 0x4108 0x4...

Page 152: ...152 Service Codes ...

Page 153: ...120 Ωs between the CAN lines high and low at one end of the CAN bus and another termination resistor of 120 Ωs between the CAN lines at the other end of the CAN bus This makes a resultant end termination of 60 Ωs Note Refer to the MCU installation guide for more details on installation and deinstallation procedure including safety warning considerations To correctly diagnose the faulty system conn...

Page 154: ...154 Service Codes Connector type 1 and type 2 pinouts Expected resistance measurement between CAN ports ...

Page 155: ... low pin C to CAN 2 high pin D CAN 1 low pin A to Ground CAN 1 high pin B to Ground CAN 2 low pin C to Ground CAN 2 high pin D to Ground Connector type 2 CAN 1 low pin 9 to CAN 1 high pin 16 CAN 2 low pin 2 to CAN 2 high pin 10 CAN 1 low pin 9 to Ground CAN 1 high pin 16 to Ground CAN 2 low pin 2 to Ground CAN 2 high pin 10 to Ground Are all measurements comply with the CAN port measurements table...

Page 156: ...stance on both sides of the CAN bus used No Reconnect the VMU ECU interface harness connector to the MCU Turn ignition ON Connect to the MCU with ODIN to check the SysFile Does the same SysFile ID occur again Yes Complete No Yes Defective MCU Replace MCU Switch ON the auxiliary batteries switch Refer to the Dana TM4 product installation guide for more details on installation and deinstallation pro...

Page 157: ...ort circuited to be raised while the motor speed was greater than the threshold of that warning The ECU VMU controller could have registered a fault at its level and shutdown the MCU In that case the source of the problem must be investigated at the ECU VMU controller level Note Refer to the Application Note High speed fault management document To correctly diagnose the faulty system connect the D...

Page 158: ...158 Service Codes ...

Page 159: ...om a lower level error type To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Referred by SysFile ID Condition Possible Causes Operational 0x0506 0x0507 0x0508...

Page 160: ...160 Service Codes ...

Page 161: ... raised upon signal openings or intermittence between the MCU and the motor through the motor sensor cable To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the Troubleshooting Tree procedure below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics System Mode Re...

Page 162: ...veform if the MCU goes in faulty state it will capture a BlackBox upon the reported error s The BlackBox can then be consulted via ODIN tool to see if the angle waveform saw tooth is straight on each rising and falling edges See below examples of waveform ...

Page 163: ...ckBox View BlackBox Check the Motor Resolver Angle Waveform Turn ignition ON Connect to the MCU with ODIN Switch ON the auxiliary batteries switch Complete Perform a road test to check further error occurrences of the original event code Connect to the MCU with ODIN and check the SysFile Does the same SysFile ID occur again No Yes Defective motor Replace motor Disconnect the motor flange Yoke from...

Page 164: ...nect the motor sensor Interface connector from the motor B Disconnect the motor sensor connector at the MCU side Refer to the Verify Connector Integrity Subtree STT01 Yes Is there any evidence of an integrity loss on the motor sensor interface connector Investigate the connector integrity of the motor sensor interface connector on the MCU Investigate the connector integrity of the motor sensor int...

Page 165: ...onnector pinout information To correctly diagnose the faulty system connect the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the procedure of Troubleshooting Tree below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Amphenol type connector Related TT External input Possible Causes TT03 TT04 TT05 TT28 TT29...

Page 166: ...imeter validate the conductivity between both ends of the harness connector for each pin No No Reconnect the harness connector to the product MCU or motor No Does the same SysFile ID occur again Yes Replace the harness connector Does the same SysFile ID occur again Complete No Yes Is one of the product connector pins not attached properly and tends to move towards the inside of the product Using a...

Page 167: ...the Diagnostic Tool see Diagnostics section for test equipment and descriptions and follow the procedure of Troubleshooting Tree below See Safety Warnings and Troubleshooting Tips sections for general guidelines on system diagnostics Related Process The STT02 call the following process Appendix 5 Cooling agent precautions Related TT External input Possible Causes TT21 TT22 TT23 TT24 TT25 TT30 None...

Page 168: ... correct the issue with the cooling hoses Is there any leaks noticeable within the cooling circuit Investigate correct the issue with the leak s Is there air within the cooling circuit Bleed the cooling circuit from any air Refer to integration vehicle installation manual Yes STT02 Yes Yes Inspect the cooling circuit for leaks A No Visually inspect all the cooling hoses in the cooling circuit for ...

Page 169: ...agent and add proper cooling agent mixture in the cooling system Refer to integration vehicle installation manual Note on cooling agent Wrong cooling agent can create dust rust in the cooling circuit Yes Wait 10 minutes before taking any further action Yes No No No Inspect the cooling circuit radiator Refer to integration vehicle installation manual No issue with the cooling circuit refer to the i...

Page 170: ...o the Board 26 0x0318 Error Board 0x18 Error related to the Board 26 0x0319 Error Board 0x19 Abnormal battery current condition as not operational Abnormal battery current condition as not operational 6 0x0321 Warning Board 0x21 motor temperature sensor A1 was shorted to Vaux 5 0x0322 Warning Board 0x22 motor temperature sensor A1 was disconnected or shorted to Vaux 5 0x0323 Warning Board 0x23 mot...

Page 171: ...Initialisation of motor control timed out 12 0x0505 Error Sequencer 0x05 Invalid traction state Invalid Traction Control state 12 0x0506 Error Sequencer 0x06 Motor control in wrong state Motor control is no longer in standby state 39 0x0507 Error Sequencer 0x07 Activation failed Traction control activation sequence failed 39 0x0508 Error Sequencer 0x8 Activation timed out Traction control activati...

Page 172: ...x1102 Error NvdProtectedSection 0x02 Error related to the NvdProtectedSection 26 0x1103 Error NvdProtectedSection 0x03 Error related to the NvdProtectedSection 26 0x1106 Error NvdProtectedSection 0x06 Data has not been read Data has not been read from non volatile memory 26 0x1200 Error ParamDrv 0x00 Error related to the ParamDrv 15 0x1201 Error ParamDrv 0x01 Error related to the ParamDrv 26 0x120...

Page 173: ...Error Motor Control Inverter 0x0B High power battery voltage reached the high limit The voltage of high power battery reached the high limit 20 0x310C Error Motor Control Inverter 0x0C High power battery voltage reached the high limit H W detection The voltage of high power battery reached the high limit HW detection 20 0x310D Error Motor Control Inverter 0x0D Temperature too high A MCU internal c...

Page 174: ...MCU phase 6 current reached the maximum The MCU phase 6 current reached the maximum limit 28 0x3207 Warning Motor Control Machine 0x07 Sum of MCU phase 4_5_6 currents exceeds maximum limit The MCU phase 4_5_6 current sum reached the maximum limit 29 0x320C Error Motor Control Machine 0x0C Error related to the MotorControl 30 0x320D Error Motor Control Machine 0x0D Error related to the MotorControl...

Page 175: ... not specified Resolver type not specified in Mac Feature Code 7 0x3313 Error Invalid Resolver Type Invalid resolver type in Mac Feature Code 7 0x3400 Warning Resolver 1 Parity error Parity error in communication with decoder chip 5 0x3401 Warning Resolver 2 Abnormal signals Resolver square sum of signal is invalid 5 0x3402 Warning Resolver 3 Broken cos line Resolver cos line disconnection detecte...

Page 176: ...ng ComClient 0x06 VmuCommand2 CommandMode is invalid VmuCommand2 CommandMode is invalid 36 0x4007 Warning ComClient 0x07 VmuCommand2 OperationalMode is invalid VmuCommand2 OperationalMode is invalid 36 0x4008 Warning ComClient 0x08 VmuCommand1 OperationRequest is invalid VmuCommand1 OperationRequest is invalid 36 0x4009 Warning ComClient 0x09 VmuCommand1 MinBatteryVoltage voltage is out of range V...

Page 177: ...out specification 37 0x4015 Warning ComClient 0x15 VmuCommandSafety timeout VmuCommandSafety timeout message has not been received within CAN protocol timeout specification 37 0x4018 Warning ComClient 0x18 Invalid polling request ID Invalid polling request ID 36 0x4019 Warning ComClient 0x19 An invalid message ID has been asked for encoding Error related to the communication protocol 36 0x401A War...

Page 178: ...is out of range maximum battery voltage is out of range 36 0x4108 Warning CAN RX Maximum battery discharge current is out of range maximum battery discharge current is out of range 36 0x4109 Warning CAN RX Maximum battery charge current is out of range maximum battery charge current is out of range 36 0x410B Warning CAN RX A message received had the wrong DLC One of the protocol message was receiv...

Page 179: ...id 5 0x4B01 Warning CoilTempSensorMgr 0x01 Motor temperature sensor B1 is invalid Warning Motor temperature sensor B1 is invalid 5 0x4B02 Warning CoilTempSensorMgr 0x02 Motor temperature sensor C1 is invalid Warning Motor temperature sensor C1 is invalid 5 0x4B03 Warning CoilTempSensorMgr 0x03 None of the motor temperature sensors is valid Warning None of the motor temperature sensors is valid 5 0...

Page 180: ... Calculated checksum is not the same as the one received in the VmuFastCommand message 36 0x4F11 Warning CAN RX VmuFastCommand rolling counter not changing The fast command rolling counter is not changing 36 0x4F12 Warning CAN RX VmuSlowCommand rolling counter not changing The slow command rolling counter is not changing 36 0x4F21 Warning CAN RX BMU1_1 timeout Timeout occurred on BMU1 message 1 36...

Page 181: ...U 03 0x0313 1 DCDC not regulating auxiliary DC voltage correctly 2 High auxiliary load being activated causing voltage drop 3 The auxiliary vehicle battery does not operate correctly 4 Intermittent or bad Vaux connection at the MCU 5 Vaux Fuse burnt 6 Defective MCU 04 0x0314 1 DCDC system not regulating auxiliary DC voltage correctly 2 Intermittent contact to the auxiliary vehicle battery that can...

Page 182: ...ured 2 Another system opens the HVIL loop from the HVIL input of the MCU 3 Defective VMU MCU interface connector on the MCU 4 Defective MCU 10 0x032F 0x0330 1 MCU HVIL parameters were not properly configured 2 MCU phase cables not inserted properly with locking screws installed 3 Motor phase cables not inserted properly with locking screws installed 4 DC input cables not inserted properly with loc...

Page 183: ...0x310A 1 DC high power contactor issue 2 DC high power battery source issue 3 DC high power battery chain connection issue contactor PDU pre charge circuit and MCU BMS 4 Improper grounding MCU and or motor 5 DC system load activation deactivation 6 Defective controller 7 Defective MCU 20 0x310B 0x310C 1 Significant voltage drops meaning numerous repeated connections and reconnections contactor or ...

Page 184: ...oling liquid flow too low or nil cooling pump issue 4 Cooling liquid temperature too high 5 Wrong cooling agent mixture used can create dust rust in the cooling circuit 6 Active short circuit mechanism activated for more than 2 minutes without speed reduction under safe back EMF voltage 7 Defective motor 25 0x3405 1 Air in the cooling circuit 2 Cooling liquid flow too low or nil cooling pump issue...

Page 185: ...h for the motor speed verify cooling 3 Defective MCU 4 Defective motor 31 0x320D 1 Phase cable connections not properly assembled on inverter or motor 2 Wrong phase cables order 3 Motor resolver signal incoherence intermittence signal distorted signal 4 Defective MCU 5 Defective motor 32 0x320E 1 Another system on the same DC bus had a sudden loss of insulation 2 Outdate software 3 Damaged phase c...

Page 186: ...019 0x401A 0x401B 0x401C 0x401E 0x4020 0x4021 0x4022 0x4023 0x4101 0x4102 0x4103 0x4104 0x4105 0x4106 0x4107 0x4108 0x4109 0x410B 0x410D 0x410E 0x410F 0x4110 0x4111 0x4112 0x4F01 0x4F02 0x4F03 0x4F04 0x4F05 0x4F06 0x4F07 0x4F08 0x4F09 0x4F0B 0x4F0D 0x4F0E 0x4F0F 0x4F10 0x4F11 1 Verify MCU CAN protocol document for protocol requirements ...

Page 187: ...Cable or harness 3 Defective CAN network 4 Defective MCU 38 0x050B 0x050C 1 The VMU ECU has sent a shutdown request to the MCU during operation causing this error to be raised 2 Defective MCU 39 0x0506 0x0507 0x0508 0x0509 0x050A 0x050D 1 Some other error caused the SysFile to be raised 40 0x3407 1 This warning can potentially cause the 0X320D error to be raised 2 Abnormal transmission inconsisten...

Page 188: ...d wait until it comes back to 0 by itself 8 Follow recommended power off and power on cycle to ensure that the unit has properly saved All EEPROM sections The new parameters will take effect in the MCU control only on the next power ON 9 It is possible to save all the parameters under Drive subfolder in one file that could be used to upload in another MCU First delete the Motor subfolder since thi...

Page 189: ...with appropriate Auxiliary Vehicle Battery Vaux supply and IGNITION MCU input to high Vaux level 2 Open Odin Server 1 and establish connection to the MCU 3 Make sure that at the bottom left of the Odin screen Device Connected is displayed in green text 4 Select the Diagnostic GDD menu ...

Page 190: ...er pressure Full comprehension of the cooling system is mandatory Necessary precautions should be observed to avoid injuries The cooling agent contains ethylene glycol that is a highly flammable product Ethylene glycol can burn with an invisible flame that can cause serious burns and or other injuries Always handle the cooling agent carefully wearing appropriate safety clothing and eyeglasses The ...

Page 191: ...l Device disconnected in yellow is shown in the ODIN status bar From a previous power ON this could take up to 10 seconds maximum 8 From the TM4 ODIN menu select Configuration Flash program manager Note A message is displayed asking if you want to save the current workspace before programming another package if you want to keep a copy of the workspace save it as an odn4 file If you do not choose t...

Page 192: ...http www dana com The Application Engineering Department must approve all applications Specificationsand ordesignaresubjecttochangewithoutnoticeorobligation Printed in USA Dana TM4 Inc 135 Joseph Armand Bombardier 25 Boucherville Québec J4B 8P1 Canada www dana com TM4 ...

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