Eaton Fuller Hybrid Transmission ePTO Test

Eaton Fuller Hybrid Transmission ePTO Test Overview

The ePTO feature allows the diesel engine to remain off for extended periods of time during PTO usage. The DC/DC Converter is energized only in ePTO mode so it can charge the 12-volt battery system. The Hybrid Control Module (HCM) operates the Motor/Generator to power the transmission mounted PTO. If the high-voltage batteries get low, the HCM starts the engine with the Motor/Generator or the standard 12-volt system.
Select ePTO mode by pressing the Mode button on the Push Button Shift Control. Some applications use a Chassis or Body Controller to control the PTO and send information to the HCM. Other applications use the HCM to control and confirm engagement of the PTO. The Body Controlled option is referred to as the J1939 option and the HCM controlled is referred to as the Analog option.
Note: To determine which module is controlling the PTO, connect ServiceRanger and select the “Roadranger Configurations” screen. Under the Hybrid Control Module option is a listing for PTO Feedback, which is either Analog Controlled (HCM), or J1939 Controlled (Body Controller).
Note: This symptom-based test should only be performed as directed by a diagnostic procedure and you have no Active fault codes.

Eaton Fuller Hybrid Transmission ePTO Test Detection

The following symptoms may have been experienced:

  • ePTO light does not illuminate when mode is selected.
  • ePTO light flashes and the push button tone sounds.
  • ePTO light is lit, but the hydraulic lift does not operate when the controls are used.
  • ePTO light is lit, but the PTO pump fails to turn off after PTO usage.
  • ePTO light is lit, but the diesel engine runs frequently or all the time.

This symptom can be caused by any of the following:

  • Transmission not in neutral
  • HCM System Fault
  • TECU system fault
  • PTO Pump
  • HCM
  • Body hydraulic pressure and demand switches
  • Boom or Outrigger switches
  • Hybrid System Harness
  • Hood Switch
  • PTO Ball Switch
  • TECU
  • PBSC

Eaton Fuller Hybrid Transmission ePTO Test

Component Identification:

Messages from the Body Controller to the HCM

Parameter Signal Value Meaning Description
520354 OK to Crank 0 No OK Body Controller will allow the Hybrid HCM to automatically start the engine in ePTO if necessary.
1 OK
520365 PTO Engaged 0 Disengaged Body Controller is confirming the PTO is engaged.
1 Engaged
520353 Request Engine Run 0 No Request Body Controller is requesting the HCM to start the engine.
1 Request
520352 Hydraulic Demand (PTO) 0 No Demand Body Controller is requesting the Hybrid to turn the transmission and provide PTO power.
1 Demand
520351 PTO Engaged Command 0 False TECU is sending the request to the HCM
1 True
520350 PTO Engaged Feedback 0 False HCM is confirming it received the message.
1 True

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

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

STEP 1. Verify “ePTO” light operates.

  1. Only perform this symptom test if directed by the Symptom-Driven Diagnostic Index and there are no Active fault codes.
  2. Key on.
  3. Press ePTO on the Push Button Shift Control:
    • If ePTO light is lit on the Push Button Shift Control, go to Step 2.
    • If ePTO light is not lit on the Push Button Shift Control, replace the Push Button Shift Control (see Shift Control). Make sure the following fault codes are not Active 16, 35, 24, 48, or 59. Go to Step 16.
    • If ePTO light is flashing on the Push Button Shift Control and the tone sounds, go to Step 6.

STEP 2. Verify Hydraulic Lift operation.

  1. Use the controls to operate the Hydraulic Lift.
    • Hydraulic Lift operates, go to Step 3.
    • Hydraulic Lift does not operate, go to Step 11.

STEP 3. Determine the run time appropriate for application and verify PTO Pump shuts down.

  1. Release the controls on the hydraulic lift and let the vehicle set:
    Note: The run time may vary depending on the type of system and size of accumulators that need to be charged.

    • PTO Pump shuts off, go to Step 4.
    • PTO Pump continues to operate, go to Step 12.

STEP 4. Verify the State of Charge and verify that diesel engine turns on and shuts down.

  1. Operate the Hydraulic controls until the diesel engine turns on.
  2. Connect ServiceRanger and select the Data Monitor option.
  3. View the high-voltage battery list and view the PID 133 “Battery State Of Charge (SOC)”:
    • If diesel engine cycles on for some time then shuts back down, test is complete.
      Go to Step 16.
    • If diesel engine never cycles on and PID 133 “Battery SOC” is less than 23%, concern with engine. The hybrid system will attempt to start the engine when the SOC goes below 23%. Contact the OEM for repair procedures.
    • If diesel engine never cycles on and PID 133 “Battery SOC” is greater than 23%, battery SOC must be below 23% before the hybrid system will request the engine to start. Continue to operate the hydraulic controls until the engine comes on.
    • If Diesel engine cycles on and never shuts down, and PID 133 “Battery SOC” is less than 68%, go to Step 5.
    • If diesel engine cycles on and never shuts down, and PID 133 “Battery SOC” is greater than 68%, go to Step 5.

STEP 5. Purpose: Confirm “Request Engine Run” signal is present at low State Of Charge.

  1. Connect ServiceRanger to the 9-Way Diagnostic Connector.
  2. View the Data Monitor parameter PID 152 “Request Engine Run”:
    • If PID 152 “Request Engine Run” reads 0 (No Request) and PID 133 “Battery SOC” is less than 68%, the current power usage is enough to require the engine to remain on so the system can deliver the power demands. If the power demands are reduced the engine should shut down because the SOC will go over 68%.
    • If the PID 152 “Request Engine Run” reads 0 (No Request) and PID 133 “Battery SOC” is greater than 68%, contact Eaton at 1- 800-826-HELP (4357).
    • If PID 152 “Request Engine Run” reads 1 (Request), the Body Controller is requesting the engine to remain on. This may be a leak in the air system or a low 12-volt system. Contact the OEM for repair procedure.

STEP 6. Visually observe the Gear Display after power up.

  1. Observe the Gear Display:
    • If gear display shows a solid “N” or number, go to Step 7.
    • If gear display shows a “PD”, the vehicle is in a diagnostic mode. To exit this mode, turn key off for 2 minutes and then turn key back on. Go to Step 6.

STEP 7. Verify the Neutral light is operational.

  1. Press the N on the Push Button and observe the light:
    • Light is displayed solid, go to Step 8.
    • Light is flashing, repair the concern with the transmission not achieving neutral. Go to the Hybrid Diagnostic Procedure.

Step 8. Confirm ePTO Mode Confirmation signal

  1. Connect ServiceRanger to the 9-Way Diagnostic Connector.
  2. View the Data Monitor parameter PID 164 “ePTO Mode Confirmation”:
    • If PID 164 “ePTO Mode Confirmation” reads 1 (True), go to Step 9.
    • If PID 164 “ePTO Mode Confirmation” reads 0 (False), go to Step 13.

Step 9. Confirm ePTO Engaged signal

  1. View the Data Monitor parameter PID 149 “PTO Engaged”:
    • If PID 149 “PTO Engaged” reads 1 (Engaged), go to Step 10.
    • If PID 149 “PTO Engaged” reads 0 (Disengaged), contact Eaton at 1- 800-826-HELP (4357).

Step 10. Confirm ePTO Request signal

  1. View the Data Monitor parameter PID 163 “ePTO Request”:
    • If PID 163 “ePTO Request” reads 1 (True), contact Eaton at 1-800-826-HELP (4357).
    • If PID 163 “ePTO Request” reads 0 (False), concern is with mechanical problem to the PTO, electrical power to PTO circuit, air pressure, or signal wire from PTO. Contact the OEM for repair procedures.

Step 11. Verify Hydraulic Demand and Battery SOC status during hydraulic operation.

  1. 1. Operate the Hydraulic Lift while monitoring the Data Monitor parameters:
    • PID 151 “Hydraulic Demand” located in the “ePTO” list
    • PID 133 “Battery SOC” located in the “HV Battery” list
      • If PID 151 “Hydraulic Demand” reads 1 (Demand) and PID 133 “Battery SOC” is greater than 23%, concern is with the PTO Pump. Contact the OEM for repair procedure.
      • If PID 151 “Hydraulic Demand” reads 1 (Demand) and PID 133 “Battery SOC” is less than 23%, concern is engine not starting to recharge the hybrid System. The hybrid system will request the engine to start when the SOC is less than 23%. Contact the OEM for repair procedures.
      • If PID 151 “Hydraulic Demand” reads 0 (No Demand), concern is with lack of hydraulic demand on the HCM from the Body Controller which can be caused by a faulty pressure switch/transducer. Contact the OEM for repair procedure.

Step 12. Confirm Hydarulic Demand signal

  1. Release the hydraulic controls.
  2. Connect ServiceRanger and select the Data Monitor option.
  3.  View PID 151 “Hydraulic Demand” under the ePTO list:
    • If PID 151 “Hydraulic Demand” reads 1 (Demand), concern with the constant Hydraulic demand from the Body Controller. Contact the OEM for repair procedures.
    • If PID 151 “Hydraulic Demand” reads 0 (No Demand), contact Eaton at 1- 800-826-HELP (4357).

Step 13. Verify no Active fault codes.

  1. Key on.
  2. Connect ServiceRanger to the 9-Way Diagnostic Connector.
  3. Ensure there are no TECU or HCM fault codes 66, 87, 18, 97, or 8.

Step 14. Verify no output speed, transmission. is in neutral and no gear is requested.

  1. View the following Data Monitor parameters from the “Hybrid Transmission” list and make sure they match the required values:
    • PID 191 Output Shaft Speed = 0 RPM
    • SPN 524 Select Gear = 0
    • SPN 523 Current Gear = 0
      • If all the parameters on ServiceRanger match the values shown, go to Step 15.
      • If the parameters on ServiceRanger do not match the values shown, turn the ignition key off for two minutes then power back up and read the values again. If the values still do not match, contact Eaton at 1- 800-826-HELP (4357).

Step 15. Confirm OK to Crank status

  1. View the following Data Monitor parameters from the “Hybrid ePTO” list and make sure they match the required values:
    • PID 153 “OK to Crank” = 1
    • If PID 153 “OK to Crank” reads “1”, contact Eaton at 1-800-826-HELP (4357).
    • If PID 153 “OK to Crank” reads “0”, concern is with the Hood Switch reading an open or the Parking Brake Switch reading not applied. Contact the OEM for repair procedures.

STEP 16. Verify repair.

  1. Key off.
  2. Reconnect all connectors.
  3. Key on.
  4. Place Shift Control into ePTO Mode:
    • If PTO system operates, test is complete.
    • If PTO system does not operate, find error in testing, go to Step 1.

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