[fusion_builder_container hundred_percent=”yes” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” status=”published” publish_date=”” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”35″ margin_bottom=”” padding_top=”” padding_right=”” padding_bottom=”” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Eaton Fuller Fault Code 4 Motor / Generator Rotation Speed Sensor

[/fusion_text][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_builder_container hundred_percent=”no” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” status=”published” publish_date=”” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”” padding_right=”” padding_bottom=”” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

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.

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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:

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”1_2″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”13934|400″ max_width=”” style_type=”” blur=”” stylecolor=”” hover_type=”none” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”no” gallery_id=”” lightbox_image=”” lightbox_image_id=”” alt=”Delphi 56-Way Mating Connector View” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.globaltransmissionsupply.com/wp-content/uploads/Delphi-56-Way-Mating-Connector-View-400×242.jpg[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Delphi 56-Way Mating Connector View

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Resolver Harness View (Front Side)

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

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”13965|800″ max_width=”” style_type=”” blur=”” stylecolor=”” hover_type=”none” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”no” gallery_id=”” lightbox_image=”” lightbox_image_id=”” alt=”Eaton Fuller Inverter motor generator resolver connection” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.globaltransmissionsupply.com/wp-content/uploads/Eaton-Fuller-Inverter-motor-generator-resolver-connection-800×361.jpg[/fusion_imageframe][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_builder_container hundred_percent=”no” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” status=”published” publish_date=”” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”” padding_right=”” padding_bottom=”” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Component Identification MY09 System:

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”2_3″ layout=”1_2″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”14000|full” max_width=”” style_type=”” blur=”” stylecolor=”” hover_type=”none” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”no” gallery_id=”” lightbox_image=”” lightbox_image_id=”” alt=”Deutsch 40-Way Mating Connector View” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.globaltransmissionsupply.com/wp-content/uploads/Deutsch-40-Way-Mating-Connector-View.jpg[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

Deutsch 40-Way Mating Connector View

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_3″ layout=”1_2″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”14028|full” max_width=”” style_type=”” blur=”” stylecolor=”” hover_type=”none” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”no” gallery_id=”” lightbox_image=”” lightbox_image_id=”” alt=”Eaton Terminal Side – Harness Connector Resolver Deutsch 6-pin connector” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.globaltransmissionsupply.com/wp-content/uploads/Eaton-Terminal-Side-Harness-Connector-Deutsch-6-pin-connector.jpg[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””]

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.

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”14029|800″ max_width=”” style_type=”” blur=”” stylecolor=”” hover_type=”none” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”no” gallery_id=”” lightbox_image=”” lightbox_image_id=”” alt=”Eaton invertor motor generator resolver MY09″ link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.globaltransmissionsupply.com/wp-content/uploads/Eaton-invertor-motor-generator-resolver-MY09-800×361.jpg[/fusion_imageframe][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_builder_container hundred_percent=”no” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” status=”published” publish_date=”” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”” padding_right=”” padding_bottom=”” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_modal name=”warnings_cautions” title=”Warnings & Cautions” size=”large” background=”” border_color=”” show_footer=”yes” class=”” id=””]

Danger: Danger indicates you will be severely injured or killed if do not follow the indicated procedure.
Warning: Warning indicates an immediate hazard, which could result in severe personal injury if you do not follow the indicated procedure.
Caution: Caution indicates vehicle or property damage could occur if you do not follow the indicated procedure.

Note: Note indicates additional detail that will aid in the diagnosis or repair of a component/system.

Follow the specified procedures in the indicated order to avoid personal injury:

1. If the high-voltage cones are around the vehicle and the lockout is installed on the PEC, the only person that should be allowed to start the vehicle is the person who signed the lockout tag.
2. Before working on a vehicle or leaving the cab while the engine is running, you should place the shift lever in “N” set the parking brake, and block the wheels.
3. For safety reasons, always engage the service brakes prior to selecting gear positions from “N.”
4. Before starting a vehicle always be seated in the driver’s seat, select “N” on the shift control, and set the parking brakes.
5. In vehicles with ePTO, the engine and/or
Motor/Generator can start in ePTO mode. Never perform any maintenance or work on vehicle, while in this mode.
6. 12-Volt Battery positive (+) and negative (-) must be disconnected prior to any welding on any Hybrid equipped vehicle.

Caution: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Caution: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
Caution: To avoid damage to the transmission during towing place the shift lever in “N” and lift the drive wheels off the ground or disconnect the driveline.

High-Voltage Warnings & Cautions

Use CO2 or Dry Chemical Fire Extinguishers.
The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with warning labels at the connectors.
All Eaton® Hybrid Diesel/Electric vehicles will be marked ‘Hybrid’ on the outside of the vehicle, along with the shift label on the dash.
Refer to OEM for specific location of chassis mounted hybrid components.
Do NOT cut into the orange high-voltage cables.
Do NOT cut into or open the PEC.
Do NOT cut into or open the DC/DC Converter.
Do NOT cut into or open the Inverter.

A buffer zone must be set up and high-voltage insulated rubber gloves (class 0 with leather protectors) are required prior to working on high-voltage. Failure to follow these instructions may result in severe personal injury or death.
The rubber-insulated gloves that must be worn while working on the high-voltage system are class 0 with leather protectors. The rubber gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in “Diagnostic Tools/Service Publications” on page 6. Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 should be followed. Failure to follow these instructions may result in severe personal injury or death.
The Lockout and Tagout devices should only be removed by the technician that placed the Lockout and Tagout devices on the vehicle. Failure to follow these instructions may result in severe personal injury or death.
High-voltage rubber insulated gloves (class 0 with leather protectors) must be worn when working on any
high-voltage cables. The “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 must be followed prior to removing any high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.
High-voltage cables and wiring are orange and contain a warning label at the connectors. High-voltage components are marked with a label. High-voltage rubber insulated gloves (class 0 with leather protectors) must be used when working on any of these components. Failure to follow these instructions may result in severe personal injury or death.

High-Voltage Service Shutdown Procedures

1. Follow “High-Voltage Work Area” procedure.
2. Locate the red PEC Service Switch on the front of the PEC and push switch off.
3. Remove the Service Switch Cover and install the Lockout Bracket (J48506).
4. Fasten tag to the Lockout Bracket.
5. Ensure the PEC Service Switch can not move from the off position.
6. Allow the system to set for a minimum of 5 minutes to discharge high voltage.
7. Connect ServiceRanger and view the Data Monitor PID 116 called “High-Voltage Battery Potential.” Use SPN 520323 for J1939 connection “Battery Voltage RB” (Relay Box).
8. The voltage should be 30 volts or less. If the voltage is above 30 volts, do not work on the vehicle and contact Eaton® at 1-800-826-HELP (4357).
9. Turn ignition key off and proceed to repair or troubleshooting step.
Note: The voltage drops to zero when the key is off.

High-Voltage Service Power-Up Procedure

1. Install all high-voltage connectors into their locked positions.
2. If you are the person working on the vehicle, remove the Lockout Bracket and tag.
3. Reinstall the Lockout Bracket over the Service Switch.
4. Pull the Service Switch out and let vehicle set for 2 minutes.
5. Start vehicle when appropriate.

[/fusion_modal][fusion_modal name=”component_location” title=”Eaton Hybrid Component and Connector Location ” size=”large” background=”#ffffff” border_color=”” show_footer=”yes” class=”” id=””]

[/fusion_modal][fusion_modal name=”component_location2″ title=”Eaton Hybrid Component and Connector Location MY09 Systems” size=”large” background=”#ffffff” border_color=”” show_footer=”yes” class=”” id=””]

[/fusion_modal][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_builder_container hundred_percent=”no” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” status=”published” publish_date=”” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”” padding_right=”” padding_bottom=”” padding_left=””][fusion_builder_row][fusion_builder_column type=”1_1″ layout=”1_1″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_image_id=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” margin_top=”” margin_bottom=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_content_boxes layout=”clean-horizontal” columns=”1″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”#f41000″ image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 1. Check for Active or Inactive fault code status.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Review and follow the Warnings & Cautions.
Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.
Key off.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.
Perform Electrical Pretest and Hybrid Electrical Pretest. (MY09 only)
Check Inverter part number. (MY09 Only)
• If Inverter is part number 4306453, contact Eaton Call Center at 1-800-826-HELP (4357)
Which FMIs are present?
- IFMI 22, 24, 25, or 27 are listed, replace the Inverter, then go to Step 4.
- If FMI 2, 23, or 26 are listed, go to Step 2.
- If FMI 3 or 21 is listed, go to Step 6.
- If FMI 0 is listed, Using ServiceRanger select the Advanced Product Functions and download the TECU and HCM snapshots then contact Eaton at 1-800-826-HELP (4357) (MY08 only). Go to step 7 (MY09 only).

[/fusion_content_box][/fusion_content_boxes][fusion_content_boxes layout=”clean-horizontal” columns=”2″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”” image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 2.Verify continuity of Resolver and Inverter components.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Key off.
Disconnect the Low-Voltage Connector at the Inverter.
Inspect for water intrusion inside wire connector.
(MY08 Only) Measure Resolver resistance at the 56-Way Harness Connector between the following pins:
- - - Pin 55 to Pin 56
    - Pin 53 to Pin 54
    - Pin 51 to Pin 52
  Note: Gently flex the Inverter 56-Way Connector Harness near the Connector while monitoring the resistance values.
  Resistance ranges for the pins are:
  - Pins 55 to Pin 56: 10.5–8.6 ohms
  - Pins 53 to Pin 54: 34–28 ohms
  - Pins 51 to Pin 52: 27–23 ohms
- If the above resistances are found, and FMI 2 is Active, contact Eaton at 1- 800-826-HELP (4357).
- If the above resistances are found, and FMI 26 or 23 are Active, replace the Inverter, then go to Step 4.
- If resistance is outside of range for any of the readings, go to Step 3.

4. (MY09 only) Determine if resistance for the Resolver at the 40-Way Harness Connector between the following pins is within the range listed:

Pin 30 to Pin 40 is 8.6–10.5 ohms
Pin 28 to Pin 38 is 28–34 ohms
Pin 29 to Pin 39 is 23–27 ohms
Note: An auto-ranging digital volt/ohm meter must be used.
- If resistance is outside of range for any of the readings, go to Step 5.
  • If resistance is within range, go to Step 3.

[/fusion_content_box][fusion_content_box title=”STEP 3. Verify continuity of Resolver Harness circuitry.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Key off.
Disconnect the 6-Way Motor/Generator Resolver Connector.
(MY08 only) Measure the Resolver resistance at the 6-Way Harness Connector between the following pins:
- - - Pin 5 to Pin 6
    - Pin 1 to Pin 3
    - Pin 2 to Pin 4
  Note: An auto-ranging digital Volt/Ohm Meter must be used.
  Resistance ranges for the pins are:
  - Pins 5 to Pin 6: 10.5–8.6 ohms
  - Pins 1 to Pin 3: 34–28 ohms
  - Pins 2 to Pin 4: 27–23 ohms
- If the above resistances are found, repair the open harness between the Inverter 56-Way Connector and the Motor/Generator 6-Way Resolver Connector, then go to Step 4.
- If resistance is outside of range, replace the Motor/Generator, then go to Step 4.

3. (MY09 Only) Measure Resolver resistance at the 40-Way Harness Connector between the following pins:

Pin 38 to Pin 40
Pin 38 to Pin 3
Pin 28 to Pin 40
Pin 28 to Pin 3
Pin 28 to ground
Pin 38 to ground
Pin 30 to ground
Pin 40 to ground
- If resistance is open or OL, replace Inverter.
- If resistance is anything other than OL, go to Step 4.

[/fusion_content_box][/fusion_content_boxes][fusion_content_boxes layout=”clean-horizontal” columns=”1″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”#f41000″ image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 4. (MY08 Only) Verify repair.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Key off.
Reconnect all connectors and the negative battery cable.
Key on.
Clear codes, see Clear Inactive Faults.
Drive the vehicle and attempt to recreate the code.
Check for codes, see View Active and Inactive Faults
- If no codes, test is complete.
- If Fault Code 4 appears, contact Eaton at 1-800-826-HELP (4357).
- If a code other than 4 appears, see Fault Code Index List.

[/fusion_content_box][/fusion_content_boxes][fusion_content_boxes layout=”clean-horizontal” columns=”2″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”” image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 4. (MY09 only) Verify continuity of Resolver Harness circuitry.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Disconnect the 6-Way motor/generator Resolver Connector (the connector going into the motor).
Measure the Resolver resistance at the 6-Way Harness Connector between the following pins:
Note: An auto-ranging digital volt/ohm meter must be used.
- Pin 1 to Pin 3
- Pin 1 to Pin 4
- Pin 2 to Pin 3
- Pin 2 to Pin 4
- Pin 1 to ground
- Pin 2 to ground
- Pin 3 to ground
- Pin 4 to ground
If resistance is open or OL, repair wiring between Resolver and Inverter.
If resistance is anything other than OL, replace the motor/generator then go to Step 8.

[/fusion_content_box][fusion_content_box title=”STEP 5. (MY09 Only) Measure resistance of Resolver circuit at motor/generator.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Disconnect 6-Way Resolver wire connector at motor/generator.
Determine if resistance on the following pins falls within the listed range:
- Pin 1 to Pin 2 is between 28–34 ohms
- Pin 3 to Pin 4 is between 8.6–10.5 ohms
- Pin 5 to Pin 6 is between 23–27 ohms
If resistance is outside of range, replace the motor/generator (Resolver is not serviceable). After repairs are made go to Step 8.
If resistance is within range, repair wiring between Resolver and Inverter. After repairs are made go to Step 8.

[/fusion_content_box][/fusion_content_boxes][fusion_content_boxes layout=”clean-horizontal” columns=”2″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”” image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 6. (MY09 only) Verify the resistance at the Inverter.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

1. Key off
2. Disconnect 40-Way Low Voltage Connector at the Inverter.
3. Measure Resolver resistance at the 40-Way Har-ness connector between the following pins:
  - Pin 28 to Pin 1
  - Pin 28 to Pin 6
  - Pin 29 to Pin 1
  - Pin 29 to Pin 6
  - Pin 38 to Pin 1
  - Pin 38 to Pin 6
  - Pin 39 to Pin 1
  - Pin 39 to Pin 6
    Note: An auto-ranging digital volt/ohm meter must be used.
4. If resistance is open or OL replace inverter. After repair is made go to Step 8.
5. If resistance is anything other than OL go to H.

[/fusion_content_box][fusion_content_box title=”STEP 7. (MY09 Only) Verify overspeed condition by test driving the vehicle.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

1. Test drive vehicle to verify an overspeed condition. This may require a downhill road condition, verify with customer the road condition when fault was set.
- If FMI 0 is set in a true overspeed condition, vehicle will need to be slowed down to prevent overspeed condition.
- If possible, update HCM software version number 672 or higher. If vehicle has HCM with primary hardware version 4306455, the most current software version available is 663. To update software version 672 or higher requires an HCM with hardware version 4306473. Hardware version number can be found in Service Ranger under Product Configurations, HCM, Primary Hardware Version.

[/fusion_content_box][/fusion_content_boxes][fusion_content_boxes layout=”clean-horizontal” columns=”1″ title_size=”18px” heading_size=”3″ title_color=”#ffffff” body_color=”#ffffff” backgroundcolor=”#4f4f4f” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” icon_circle=”” icon_circle_radius=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” icon_size=”” icon_hover_type=”” hover_accent_color=”#f41000″ image=”” image_id=”” image_width=”” image_height=”” link_type=”” button_span=”” link_area=”” link_target=”” icon_align=”left” animation_type=”” animation_delay=”” animation_offset=”” animation_direction=”left” animation_speed=”0.3″ margin_top=”” margin_bottom=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][fusion_content_box title=”STEP 4. (MY09 Only) Verify repair.” backgroundcolor=”” icon=”” iconflip=”” iconrotate=”” iconspin=”no” iconcolor=”” circlecolor=”” circlebordersize=”” circlebordercolor=”” outercirclebordersize=”” outercirclebordercolor=”” image=”” image_id=”” image_width=”” image_height=”” link=”” linktext=”Read More” link_target=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]

Key off.
Reconnect all connectors and the negative battery cable.
Key on.
Clear codes, see Clear Inactive Faults.
Drive the vehicle and attempt to recreate the code.
Check for codes, see View Active and Inactive Faults
- If no codes, test is complete.
- If Fault Code 4 appears, contact Eaton at 1-800-826-HELP (4357).
- If a code other than 4 appears, see Fault Code Index List.

[/fusion_content_box][/fusion_content_boxes][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_global id=”13788″]