Eaton Fuller Fault Code 4 Motor / Generator Rotation Speed Sensor

Fault code for Eaton Hybrid Drive Systems models (MY08) EH-8E306A-U, EH-8E306A-UPG, EH-8E306A-UP, EH-8E306A-CD, EH-8E306A-T, EH-6E606B-CD, (MY09) EH-8E406A-U/P, EH-8E406A-UP, EH-8E406A-UPG, EH-8E406A-CD, EH-8E406A-CDG, EH-8E406A-CDR, EH-8E406A-T, EH-6E706B-CD, EH-6E706B-P and EH-6E706B-UPG. The Motor/Generator Rotation Speed Sensor is mounted to the back of the Motor/Generator around the Input Shaft. The sensor (two-piece design) is a rotor mounted to the Input Shaft and a Sensing Ring mounted to the motor housing. The Sensing Ring is supplied with low-voltage during operation. The rotor turns inducing a voltage fluctuation into the Sensing Ring, which is then converted into a digital signal for Motor/Generator RPM. Voltage output and frequency is low at idle and increases with RPM.

Fault Code 4 – Motor/Generator Rotation Speed Sensor Detection

  • Inverter ignition voltage is greater than 7 volts and less than 16 volts.
  • FMI 2 does not set if there is an Active Transmission Input Shaft Speed Sensor fault.

Conditions to Set Fault Code Active

Conditions to Set Faul Code Active:

  • FMI 0 is set when the Motor/Generator speed exceeds the normal allowable range.
  • FMI 2 is set when the Motor/Generator speed is different than Transmission Input Shaft Speed by more than 100 RPM for at least 10 seconds.
  • FMI 3: Set when the resolver circuit is shorted to ground.
  • FMI 21: Set when a resolver signal line short to 12-volt battery or ground is detected.
  • FMI 22, 24, 25 are set when the combination of analog-to-digital converter signals are a mismatch.
  • FMI 27 is set when the Inverter detects an error during the initial check.
  • FMI 23 is set when there is an analog-to-digital converter output error signal for 100 MS.
  • FMI 26 is set when the rotation sensor speed is greater than 6000 min-1 for 10 MS.

Fallback When Fault Code 4 is set the following conditions occur:
• Amber “Check Hybrid” light illuminates.
• Fault is stored in Hybrid Control Module (HCM) memory.
• Electric Motor/Generator Assist and Regeneration are disabled; however, the high-voltage relays remain powered.
• HCM continues to control the hybrid vehicle in a diesel-only mode.
• Transmission defaults start gear to 1st.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears the faults from history after the fault has been Inactive for 200 hours

This fault code can be caused by any of the following:

MY08

  • FMI 0
    • Long extended grades may require intermittent use of the service brakes to slow the vehicle
  • FMI 22, 24, 25, 27
    • Inverter
  • FMI 2, 23, 26
    • Inverter
    • Motor/Generator
    • Resolver Harness between the Motor/Generator and Inverter

MY09

  • FMI 3, 21
    • Inverter
    • Resolver Harness between the motor/generator
      and Inverter
  • FMI 2, 22, 23, 24, 25, 27
    • Inverter
    • Motor/Generator
    • Resolver Harness between the Motor/Generator and Inverter
    • Water in Inverter or Resolver wire connector

Fault Code 4 – Motor/Generator Rotation Speed Sensor Test

Component Identification MY08 System:

Delphi 56-Way Mating Connector View

Delphi 56-Way Mating Connector View

Eaton Transmission Resolver Harness View

Resolver Harness View (Front Side)

NOTE: Refer to the Eaton Hybrid Component and Connector Location for Connector Locations in MY08 Systems

Eaton Fuller Inverter motor generator resolver connection

Component Identification MY09 System:

Deutsch 40-Way Mating Connector View

Deutsch 40-Way Mating Connector View

Eaton Terminal Side - Harness Connector Resolver Deutsch 6-pin connector

Eaton Terminal Side – Harness Connector Resolver Deutsch 6-pin connector

NOTE: Refer to the Eaton Hybrid Component and Connector Location for Connector Locations in MY09 Systems.

Eaton invertor motor generator resolver MY09

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