DANA SPICER TM4 SUMO HP HV Powertrain Troubleshooting Manual
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DANA SPICER TM4 SUMO HP HV Powertrain Troubleshooting Manual

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Dana TM4
Troubleshooting Guide
SMTS-0603
March 2022
SUMO™ HP HV Powertrain
®
1

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Summary of Contents for DANA SPICER TM4 SUMO HP HV Powertrain

  • Page 1 SUMO™ HP HV Powertrain ® Dana TM4 Troubleshooting Guide SMTS-0603 March 2022...

  • Page 2: Safety Warnings

    Dana TM4 reserves the right to discontinue or modify materials recommended for use and should not be its models and/or procedures and to change considered an endorsement.
  • Page 3 Mishandling of this product may damage the product and/or cause injury or death. • limitations specifications communicated by Dana TM4 regarding the product must be respected. • Do not attempt to open, repair or modify the Motor Control Unit (MCU). In case of...
  • Page 4 Safety Warnings WARNING CAUTION Regardless of the cooling system used, when in a It is important to ensure that no voltage is present on system, the MCU can be irreparably damaged and the high-voltage battery wires between both may become unstable if the coolant liquid pressure polarities and from each polarity to chassis before reaches or exceeds a pressure of 30 PSI (static manipulation.

  • Page 5: Table Of Contents

    TT17 ............... 90 Disclaimer ..............8 TT18 ............... 92 Safety Instructions ............ 8 TT19 ............... 94 Dana TM4 Motor and MCU Components (Example) 9 TT20 ............... 98 System Specifications (Example) ......10 TT21 ..............104 Component Description .......... 11 TT22 ..............106 Simplified System Schematic .........

  • Page 6: General Information

    General Information General Information Acronyms - Symbols TM4 ODIN Dana TM4 diagnostic software Ampere unit Universal Serial Bus Alternative Current Volt unit ACDC Alternative Current to Direct Vaux Auxiliary battery voltage (12 V or 24 V) Current Vehicle Management Unit...

  • Page 7: Key Features

    General Information Key Features Dana TM4 Motor Control Unit (MCU) Hazardous Voltage Interlock Loop (HVIL) The Motor Control Unit (MCU) system is operated via The Hazardous Voltage Interlock Loop (HVIL) internal CAN message communication between the MCU and loop is closed, resulting in a short circuit between its the Vehicle Management Unit (VMU) or Electronic two input pins.

  • Page 8: Disclaimer

    General Information Disclaimer When manipulating and/or installing this product, you Dana TM4 is not responsible for prolonged use of must NOT: product with one or more defective sensors as this could cause permanent damage to the product and • Modify any part of the MCU.

  • Page 9: Dana Tm4 Motor And Mcu Components (Example)

    General Information Dana TM4 Motor and MCU Components (Example) Dana TM4 Motor Dana TM4 MCU...

  • Page 10: System Specifications (Example)

    General Information System Specifications (Example) The motorization system is composed of the MCU and The MCU has the following connectors: • motor. Communication connector. • Refer to the System Specification guide for your Grounding Point. • system. DC connectors. The table below is an example. •...

  • Page 11: Component Description

    General Information Component Description Communication connector An interface harness is used between the MCU and the VMU/ECU. The communication harness that is connected to the MCU contains all required signals to interface the MCU with the VMU/ECU, including the enable signal, the CAN ports and the CAN signals VMU/ECU interface harness connector The communication connector has 23 pins with the following specification:...
  • Page 12 General Information Grounding Point The grounding point connection prevents functional The vehicle chassis connection points for the MCU issue to the motorization system and ensures the user and motor grounding straps should ideally be the safety in case of an insulation fault. An incorrectly same point, or the same vehicle chassis frame side.
  • Page 13 The Motor and the MCU must be connected together by motor sensor cables. Therefore, a motor sensor interface harness is required between the motor and the MCU. Motor sensor connector pinout mapping from Dana TM4 MCU to TM4 motor TM4 Motor Signal name pin out...
  • Page 14 General Information Motor connector head Identification Dana TM4 MCU A3 Dana TM4 Motor...
  • Page 15 General Information Connecting Auxiliary Battery to MCU Auxiliary Battery Fuse The Auxiliary Battery provides power to the MCU. The To protect the system against short circuit, a fuse is negative terminal of the battery must be connected to connected in series with the positive terminal of the the frame of the vehicle (chassis).
  • Page 16 General Information Embedded software packages The software installation package includes several embedded files: • The embedded software package executable • A basic TM4 ODIN file (.odn4). The next chart shows the embedded software package files: File Name Description Embedded Software MCU_INV- ABCDEFGH Pkg.exe Embedded software files Package Executable...
  • Page 17 General Information Coolant In / Out As power is delivered to the wheels, temperatures of the various components within the motor and the MCU rise. Therefore, a cooling unit/radiator must be installed in the vehicle and connected to the MCU and the motor to dissipate the excess heat.
  • Page 18 General Information Coolant Specification Safety precaution As the cooling unit, cooling hose and cooling agent are not supplied by Dana TM4, the vehicle integrator WARNING has full responsibility for following specifications and operating methods given by the system specifications Regardless of the cooling system used, the product...
  • Page 19 General Information WARNING User security: Allow for enough room for air circulation, clearance space for movement and access to cables for • Ensure that each cable is clearly identified for maintenance etc. specific usage to prevent errors during installation and operation that may damage When securing cables: the system or cause injury to the user.
  • Page 20 Refer to the Dana TM4 extranet site under your components and promoting component reliability. product family within the "Accessory" tab for the cable specifications.

  • Page 21: Simplified System Schematic

    General Information Simplified System Schematic CAN interface (with DB9 connector) With TM4 ODIN installed Cooling source USB t o CA N Cooling int erf ace (pump and radiator) configuration connect or USB port Serial or Cooling parallel CAN interface Cooling in channel «...

  • Page 22: Diagnostics

    The latest version of TM4 ODIN can be downloaded from the Dana TM4 extranet: https://extranet.tm4.com/ Note: Contact Dana TM4 if there is any issue during the installation or configuration of TM4 ODIN. Note: We will refer the TM4 ODIN software by...
  • Page 23 Diagnostics Multimeter MegΩmeter Based upon system schematics and aided by This device is used to measure the insulation of high component-specific error messages, a multimeter is voltage equipment or installation that may present a required to check continuity, resistance and voltage safety hazard in the event of a fault.

  • Page 24: Installing The Can Drivers

    Install all the CAN drivers provided with the CAN Connect the CAN ports of the CAN interface to the interface onto your computer. CAN port of the Dana TM4 product. Then connect the CAN interface to your computer. Note: You must have ADMIN access rights on your...

  • Page 25: Opening Odin

    “ODIN 4 Server 1” is preconfigured to communicate with a MCU product by default. “ODIN 4 Server 2” is preconfigured to communicate with a Dana TM4 NEURO (VMU) by default. The ODIN 4 Servers can be reconfigured to suit customer needs.
  • Page 26 Diagnostics Wait until ODIN loads the following page. Note: The following visual is an example. The visual representation of the ODIN view can be configured to suit customer needs. In the « Diagnostic » dropdown menu, 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.
  • Page 27 Diagnostics Note: The “Stop” button on the first window stops the CAN trace and gather the remaining information. At any time, you can click 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.
  • Page 28 Diagnostics Open the file. Count: SysFile counter. Event Code: 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...

  • Page 29: Sysfile Id Summary

    Diagnostics SysFile ID Summary Table of Troubleshooting Tree Note: In this document Service Code are named The table of Troubleshooting Tree provides the SysFile ID in accordance with ODIN TM4 convention. information of the: • SysFile ID are described in the Service Codes SysFile ID, •...
  • Page 30 Diagnostics Table matching SysFile IDs and Troubleshooting Trees The following table relates the SysFile ID with the Troubleshooting Tree it belongs to. SysFile ID N° TT SysFile ID N° TT SysFile ID N° TT 0x0000 0x1101 0x3303 0x000A 0x1102 0x3304 0x0312 0x1103 0x3307...
  • Page 31 Diagnostics SysFile ID N° TT 0x4102 0x4103 0x4104 0x4105 0x4106 0x4107 0x4108 0x4109 0x410B 0x410D 0x410E 0x410F 0x4110 0x4111 0x4112 0x4121 0x4122 0x4123 0x4124 0x4125 0x412D 0x4209 0x4703 0x4801 0x4B00 0x4B01 0x4B02 0x4B03 0x4F01 0x4F02 0x4F03 0x4F04 0x4F05 0x4F06 0x4F07 0x4F08 0x4F09 0x4F0B...

  • Page 32: Troubleshooting Tips

    Systems that are not provided or selected by Dana The most likely cause of electrical faults will be TM4 are not covered by this troubleshooting guide damaged wires or connections. As a first step in...

  • Page 33: Service Codes

    Service Codes Service Codes Abbreviation and Definition Abbreviation Name Description Tree that allows to diagnose the possible cause of an error, Troubleshooting Tree warning or information message given by the unit. Develops a specific and routine part of the Troubleshooting Tree. It Sub Troubleshooting Tree is used in multiple Troubleshooting Tree s (TT).

  • Page 34: Troubleshooting Tree Legends

    Indicates a sub-tree present in this Sub-tree document. Process/Actions Indicates any process or action to do. Indicates a process we describe an assistance action (Ex: “Call Dana TM4 for Assistance Process help”). Indicates a decision point between two or Question/Decision/Choice more paths in the tree.

  • Page 35: Tt01

    ON. If SysFile section was corrupted, the SysFile is cleared. In this case, a followed warning (SysFile ID Note: Refer to the Dana TM4 Product installation 0x000A) will indicate more detail upon nature of the guide...
  • Page 36 Service Codes...

  • Page 37: Tt02

    Service Codes TT02 System Mode Referred by SysFile Condition Possible Causes 1. Wrong previous shutdown sequence. Auxiliary vehicle battery (Vaux 12V or 24V) powered OFF before the MCU MCU memory section “ReadyToPowerOff” CAN status on a At start up 0x000A 0x1300 0x4209 corruption detected.
  • Page 38 Service Codes...

  • Page 39: Tt03

    Service Codes TT03 System Mode Referred by Condition Possible Causes SysFile ID DCDC not regulating auxiliary DC voltage correctly. High auxiliary load being activated causing voltage drop. MCU detected an The auxiliary vehicle battery does not Operational 0x0313 auxiliary vehicle battery operate correctly.
  • Page 40 Service Codes VMU Connector Head Identification VMU/ECU Interface (Type 2) VMU/ECU Interface (Type 1) VMU/ECU interface harness Plug Pinout (Type 2) VMU/ECU interface harness Plug Pinout (Type1) Connector (Front) (Type 2) Connector (Front) (Type 1) Wire Insertion Side (Back) (Type 1) Wire Insertion Side (Back) (Type 2)
  • Page 41 Service Codes Connector type 2 pinout Connector type 1 pinout...
  • Page 42 Service Codes Switch OFF the Disconnect VMU Switch ON the auxiliary Troubleshooting Tree 03 auxiliary batteries interface connector batteries switch. switch. from the MCU. Defective VMU/ECU interface Switch OFF the harness connector causing an Inspect the auxiliary auxiliary batteries open circuit from Vaux batteries fuse.
  • Page 43 Connect to the MCU with ODIN tool and check the SysFile. Defective MCU. Does the same SysFile ID Replace MCU. occur again? Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations. Complete...
  • Page 44 VMU/ECU solve problems. interface MCU connector? Defective MCU. Replace MCU. Complete Switch OFF the Refer to the Dana TM4 auxiliary batteries Product installation guide switch. for more details on installation and deinstallation procedure including safety warning...

  • Page 45: Tt04

    Service Codes TT04 System Mode Referred by SysFile ID Condition Possible Causes DCDC system not regulating auxiliary DC voltage correctly. Intermittent contact to the auxiliary MCU detected an vehicle battery that can cause voltage Operational 0x0314 auxiliary voltage that spikes due to load dump of the DCDC was too high.
  • Page 46 Service Codes Connector Head Identification VMU/ECU Interface (Type 2) VMU/ECU Interface (Type 1) VMU/ECU interface harness Plug Pinout (Type 2) VMU/ECU interface harness Plug Pinout (Type1) Connector (Front) (Type 2) Connector (Front) (Type 1) Wire Insertion Side (Back) (Type 1) Wire Insertion Side (Back) (Type 2)
  • Page 47 Service Codes Connector type 2 pinout Connector type 1 pinout...
  • Page 48 Connect to the MCU with Defective MCU. Does the same SysFile ID ODIN tool and check the Replace MCU. occur again? SysFile. Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations. Complete...
  • Page 49 Connect to the MCU with Does the same SysFile ID Defective MCU. ODIN tool and check the occur again? Replace MCU. SysFile. Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations. Complete...

  • Page 50: Tt05

    The loss of integrity of the motor sensor connector on the MCU leads to consider defective MCU. Note: If the motor is a Dana TM4 motor, then the expected values of the measurements should as per the Motor internal resistance measurement table. If the motor is not a Dana TM4 motor, then the measurements may be different.
  • Page 51 Service Codes Motor internal resistance measurement table...
  • Page 52 Service Codes Connector Head Identification TM4 Motor connector (Type 1) TM4 Motor connector (Type 2)
  • Page 53 Service Codes...
  • Page 54 Service Codes...
  • Page 55 Service Codes...

  • Page 56: Tt06

    Service Codes TT06 System Mode Referred by Condition Possible Causes SysFile ID 0x3113 warning occurred at the same time caused by another error while the vehicle was in high speed (Back EMF DC battery current mechanism - phase short circuit protection beyond acceptable limit engaged).
  • Page 57 Service Codes...

  • Page 58: Tt07

    Service Codes TT07 System Mode Referred by SysFile ID Condition Possible Causes Inconsistency of the motor resolver type Initialisation 0x3312 0x3313 recorded in EEPROM Defective motor. (power up) memory has been detected. Description The Troubleshooting Tree 07 indicates a warning or error where an inconsistency of the motor resolver type recorded in EEPROM memory has been detected.
  • Page 59 ODIN to check the SysFile. Does the same Defective motor SysFile ID occur Replace motor again? Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure Motor resolver type including safety warning written in the motor considerations.

  • Page 60: Tt08

    TT08 System Mode Referred by SysFile ID Condition Possible Causes MCU HVIL parameters were not correctly configured. The HVIL circuit had Another system opens the HVIL loop from Standby or an input voltage that the HVIL input of the MCU. 0x032B 0x32C Operational was outside the...
  • Page 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 Service Codes Connector type 2 pinout...
  • Page 63 Service Codes...
  • Page 64 Service Codes...

  • Page 65: Tt09

    TT09 System Mode Referred by SysFile ID Condition Possible Causes MCU HVIL parameters were not correctly configured. Another system opens the HVIL loop from Standby or The output of the the HVIL input of the MCU. 0x032D 0x032E Operational HVIL line had a fault. Defective VMU/MCU interface connector on the MCU.
  • Page 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 Service Codes Connector type 2 pinout...
  • Page 68 Service Codes...
  • Page 69 Service Codes...

  • Page 70: Tt10

    TT10 System Mode Referred by SysFile ID Condition Possible Causes MCU HVIL parameters were not properly configured. MCU phase cables not inserted properly with locking screws installed. Motor phase cables not inserted properly The HVIL line with locking screws installed. Standby or experienced an DC input cables not inserted properly with...
  • Page 71 Service Codes...
  • Page 72 Service Codes...
  • Page 73 Service Codes...

  • Page 74: Tt11

    Service Codes TT11 System Mode Referred by SysFile ID Condition Possible Causes MCU HVIL parameters were not properly configured. Standby or HVIL over current 0x0331 0x0332 HVIL power source fault. Operational fault was detected. Defective MCU. HVIL The HVIL is short for “High Voltage Interlock Loop”. To correctly diagnose the faulty system, connect the HVIL is a hardware signal, and its purpose is to Diagnostic Tool (see «Diagnostics»...
  • Page 75 Service Codes Connector Head Identification VMU/ECU Interface (Type 2) VMU/ECU Interface (Type 1) VMU/ECU interface harness Plug Pinout (Type 2) VMU/ECU interface harness Plug Pinout (Type1) Connector (Front) (Type 2) Connector (Front) (Type 1) Wire Insertion Side (Back) (Type 1) Wire Insertion Side (Back) (Type 2)
  • Page 76 Service Codes...
  • Page 77 Service Codes...

  • Page 78: Tt12

    Service Codes TT12 System Mode Referred by SysFile ID Condition Possible Causes 0x0312 0x0501 0x0502 Wrong MCU connected to the motor. 0x0503 0x0504 0x0505 Wrong motor type connected to the MCU. Initialisation 0x050E 0x050F 0x051B Error detected at Wrong software flashed to the MCU. (power up) 0x051C 0x1207 0x3111 initialization.
  • Page 79 Service Codes...
  • Page 80 Is the MCU Part Number Make sure to use the proper from your note corresponding to MCU part number that is the one found under the DANA compatible with your system. TM4 extranet folders ? Is the motor Part Number...

  • Page 81: Tt13

    Service Codes TT13 System Mode Referred by SysFile ID Condition Possible Causes Motor not compatible with the MCU Invalid motor type, software. Initialisation phase calibration or 0x120A 0x3212 0x3302 (power up) initialisation error with Third party motor not calibrated. the motor. Defective motor.
  • Page 82 Electrical sources are before taking any batteries switch. switched OFF. further action. Switch ON the Turn ignition Is the motor a Dana auxiliary batteries TM4 motor ? switch. Open ODIN, and check the status bar to see which Proceed with the motor Refer to the Dana software version is running.
  • Page 83 Service Codes Is the motor sensor cable (signal connector) connected properly between the MCU the motor? Connect the motor sensor cable properly between the MCU and the motor. (Refer to the TM4 Product installation guides). Switch ON the auxiliary batteries switch. Turn ignition ON.

  • Page 84: Tt14

    Service Codes TT14 System Mode Referred by SysFile ID Condition Possible Causes The control detects that the motor Wrong motor type connected to the MCU. connected to the Initialisation 0x2209 0x3307 MCU is not Wrong software flashed to the MCU. (power up) compatible with the Defective Motor.
  • Page 85 Service Codes...

  • Page 86: Tt15

    Service Codes TT15 System Mode Referred by SysFile ID Condition Possible Causes Inconsistency of the Protected, Global or ParamDrv EEPROM Initialisation 0x1000 0x1100 0x1200 memory section has Defective MCU. (power up) been detected through a CRC verification. Description The Troubleshooting Tree 15 indicates an error where an inconsistency in the protected, global or ParamDrv EEPROM memory section was detected through Cyclic Redundancy Check (CRC) validation.
  • Page 87 Service Codes...

  • Page 88: Tt16

    Service Codes TT16 System Mode Referred by SysFile ID Condition Possible Causes Inconsistency of the motor EEPROM Initialisation memory section has 0x2200 Defective motor. (power up) been detected through a CRC verification. Description The Troubleshooting Tree 16 indicates an error where an inconsistency in the motor EEPROM memory section was detected through Cyclic Redundancy Check (CRC) validation.
  • Page 89 Service Codes...

  • Page 90: Tt17

    Related Process Note: Replace the MCU with a MCU corresponding to the MCU subfolder specified on the Dana TM4 The TT17 call the following process: extranet site. Appendix 6: Update Software...
  • Page 91 Service Codes...

  • Page 92: Tt18

    Service Codes TT18 System Mode Referred by SysFile ID Condition Possible Causes Minor issue. Could potentially be raised due to internal noise under high DC input voltage levels. Inconsistency between the internal Defective MCU, if 0x320D or 0x3213 0x3100 0x3101 0x3102 Operational control logic and the SysFile ID also occurs within the same...
  • Page 93 SysFile ID event during the same Replace MCU. session (under the same « Info – System power-up ») ? Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning considerations Did the same...

  • Page 94: Tt19

    Service Codes TT19 System Mode Referred by SysFile ID Condition Possible Causes DC high power contactor issue. DC high power battery source issue. DC high power battery chain connection The high-power DC issue (contactor, PDU, pre-charge circuit voltage dropped and MCU, BMS). Operational under the limit and 0x310A...
  • Page 95 Service Codes Ensure all High Voltage Switch OFF the auxiliary Troubleshooting Tree 019 Electrical sources are batteries switch. switched OFF. Wait for 10 minutes before taking any further action. Was the main contactor opened before the MCU was commanded to Disconnect the High shutdown during system Voltage DC cables from...
  • Page 96 Service Codes Is there any signs Clean the input DC connection points of hot spots on the input DC using isopropyl alcohol. connection points? Are the visible signs of hot spots gone after cleaning the connectors ? Ensure that the connections points are installed correctly according to the MCU Interface drawing document.
  • Page 97 10 second (Time column) from Defective MCU. SysFile ID occur the "Info - System power-up" Replace MCU. again? after a turn Refer to the Dana TM4 ON ? product installation guide for more details on Complete installation and Possible issue with pre-charge deinstallation procedure...

  • Page 98: Tt20

    Service Codes TT20 System Mode Referred by SysFile ID Condition Possible Causes Significant voltage drops meaning numerous repeated connections and reconnections (contactor or DC battery chain intermittence). Affected motor resolver signal (motor High power DC angle waveform) that creates DC Operational voltage was higher high voltage ripple.
  • Page 99 Service Codes Note: Regarding the resolver angle waveform, 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.
  • Page 100 Service Codes Troubleshooting Tree 20 Perform a road test, with Turn ignition Turn ignition ON. ODIN connected to the OFF and ON. MCU. Connect to the MCU with ODIN and check the status bar. Does the same SysFile ID occur again? Complete Does the text...
  • Page 101 Service Codes Switch OFF the auxiliary batteries switch. By looking at the BlackBox graphic displayed, are there motor resolver angle waveform ripples (Line not straight on Ensure all High Voltage the rise or fall of the Electrical sources are saw tooth shape) switched OFF.
  • Page 102 ? Reconnect the DC High Voltage connections to the MCU according to the MCU Interface drawing document. Refer to the Dana TM4 Investigate possible contactor product installation guide for intermittence or any contacts in the more details on installation Defective MCU.
  • Page 103 Service Codes Defective grounding strap(s) or resistive Is any connection point(s). of the measured resistance over Replace grounding strap(s) or remake/fix grounding connection point(s) to comply to the product installation guides requirements. Investigate the vehicle for external root causes that might be causing Verify the DC cable shield the SysFile ID to be raised : connection to the MCU.

  • Page 104: Tt21

    Service Codes TT21 System Mode Referred by SysFile ID Condition Possible Causes Air in the cooling circuit. Cooling liquid flow too low or nil (cooling pump issue). One of the Cooling liquid temperature too high temperature sensors Wrong cooling agent mixture used – of the IGBT went Operational (can create dust/rust in the cooling...
  • Page 105 Service Codes...

  • Page 106: Tt22

    Service Codes TT22 System Mode Referred by SysFile ID Condition Possible Causes Air in the cooling circuit. One of the internal Cooling liquid flow too low or nil temperature sensors (cooling pump issue). went over the limit Cooling liquid temperature too high. Operational 0x310F 0x3110 Wrong cooling agent mixture used –...
  • Page 107 Service Codes...

  • Page 108: Tt23

    Service Codes TT23 System Mode Referred by SysFile ID Condition Possible Causes Air in the cooling circuit. Cooling liquid flow too low or nil (cooling pump issue). The internal EMI Cooling liquid temperature too high. section temperature Wrong cooling agent mixture used – measurement went Operational (can create dust/rust in the cooling...
  • Page 109 Service Codes...

  • Page 110: Tt24

    Service Codes TT24 Referred by SysFile System Mode Condition Possible Causes Another SysFile event occurred within TT05 tree. Air in the cooling circuit. Cooling liquid flow too low or nil (cooling One of the pump issue). temperature sensors of the motor coil went Cooling liquid temperature too high Operational 0x320F...
  • Page 111 Service Codes...

  • Page 112: Tt25

    Service Codes TT25 System Mode Referred by SysFile ID Condition Possible Causes Air in the cooling circuit. Cooling liquid flow too low or nil (cooling The Resolver pump issue). Converter Chip Cooling liquid temperature too high. Operational detected a resolver 0x3405 Wrong cooling agent mixture used –...
  • Page 113 Service Codes...

  • Page 114: Tt26

    These SysFile IDs is a software version issue. The user must update the software of the MCU to the last version published in Dana TM4 extranet. The MCU itself may also be defective. To correctly diagnose the faulty system, connect the Diagnostic Tool (see «Diagnostics»...
  • Page 115 Service Codes...

  • Page 116: Tt27

    Service Codes TT27 System Mode Referred by SysFile ID Condition Possible Causes The IGBT short circuit mechanism Other error causes the system to go in has been activated. failure state while in high speed (back EMF Operational This event is 0x3113 too high to maintain DC bus under the high activated under high...
  • Page 117 Service Codes...

  • Page 118: Tt28

    Service Codes TT28 System Mode Referred by SysFile ID Condition Possible Causes Short circuit between phases. The auxiliary vehicle battery not operating correctly. Intermittent or bad Vaux connection at the One or more of the MCU. phase currents Vaux Fuse about to open or more 0x3200 0x3201 0x3202 Operational reached the...
  • Page 119 Service Codes Troubleshooting Tree 28 Refer to the Application Note High-speed fault management document. The MCU must have been commanded the « Warning – Back to shut down EMF Motor (ShutdownReq via reduction mechanism activated (phases are Ignore any « phase CAN command) by short-circuited) »...
  • Page 120 Service Codes Refer to the Reconnect the VMU/ECU Dana TM4 interface connector to the MCU. product Defective MCU. installation guide Replace MCU. for more details on installation Switch ON the auxiliary batteries deinstallation switch. procedure including safety Connect to the...

  • Page 121: Tt29

    Service Codes TT29 System Mode Referred by SysFile ID Condition Possible Causes The auxiliary vehicle battery not operating correctly. The phase 1-2-3 Intermittent or bad Vaux connection at the and/or 4-5-6, current Operational MCU. 0x3203 0x3207 sum reached the Vaux Fuse about to open or more maximum limit.
  • Page 122 Service Codes...

  • Page 123: Tt30

    Service Codes TT30 System Mode Referred by SysFile ID Condition Possible Causes MCU temperature too high for the motor speed (verify cooling). There is not enough Motor temperature too high for the motor Operational defluxing current at 0x320C speed (verify cooling). high speed.
  • Page 124 Defective MCU. DriveCoolingFlowRequest field Replace MCU. higher than MotorCoolingFlowRequest while operation ? Refer to the Dana TM4 Product installation guide for more details on installation and deinstallation procedure including safety warning considerations Defective motor. Replace motor.
  • Page 125 Service Codes References...

  • Page 126: Tt31

    TM4 ODIN diagnostic tool allows to visualize the motor resolver angle waveform: see 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.
  • Page 127 Service Codes Note: Regarding the resolver angle waveform, 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.
  • Page 128 Service Codes Troubleshooting Tree 31 Ensure all High Voltage Switch OFF the auxiliary Wait for 10 minutes before Electrical sources are batteries switch. taking any further action. switched OFF. - Phase lugs have to be properly Inspect all phase connectors or screwed and ensure good contact.
  • Page 129 0x3108) raised under the switched OFF. same « Info – System power-up ? Wait for 10 minutes before taking any further action. Refer to the Dana Is the motor resolver TM4 Product cable routed away of any high installation guide...
  • Page 130 Service Codes Disconnect the motor sensor Interface connector from the motor. Investigate the connector integrity of the motor sensor interface connector on the motor. Refer to the « Verify Connector Integrity » Subtree (STT01) Is there any evidence of an Disconnect the motor sensor integrity loss on the motor sensor connector at the MCU side...
  • Page 131 POC. Does the same SysFile ID occur again? Refer to the Dana TM4 Product installation guide and operation and maintenance manual for more details Defective motor. on the phase cables configurations Replace motor.
  • Page 132 Service Codes Check the cabling for continuity between the MCU and motor grounding dedicated points and vehicle chassis grounding point(s): Vehicle chassis MCU dedicated Vehicle chassis grounding point grounding point Motor Vehicle chassis Motor dedicated Vehicle chassis grounding point grounding point - Inspect grounding straps for visible damage.

  • Page 133: Tt32

    Defective motor. Description The Troubleshooting Tree 32 indicates an error where Note: Refer to the Dana TM4 Product installation the cables (AC or DC) connecting the Motor and the guides for more details on installation and deinstallation MCU were shorted to the chassis, possibly due to a procedure including safety warning considerations.
  • Page 134 Check the compatibility of the Access to your system and software flashed to the MCU with the open all MCU, MOTOR and one published on the Dana TM4 SOFTWARE subfolders under extranet site for your system. your system. Is the software package...
  • Page 135 Service Codes Is one or more phase cables between Replace damaged phase Switch ON the auxiliary MCU and motor visibly cables. batteries switch. damaged ? Turn ignition ON. Connect to the MCU Switch OFF the auxiliary with ODIN to check the batteries switch.
  • Page 136 Voltage to check the integrity ? Electrical Defective MCU. SysFile. sources are Replace MCU. switched OFF. Refer to the Dana Is the TM4 Product problem installation guides for persists on Switch OFF the more details on installation and subsequent...
  • Page 137 Defective Motor. Is the Replace Motor. phases cable(s) damaged at the phases connection point(s) ? Refer to the Dana TM4 Product installation guides for more details on installation and deinstallation procedure including safety warning considerations Change any affected phase cable(s)
  • Page 138 Defective MCU. of any phase cable under support for assistance. Replace MCU. 10 Mohm ? Refer to the Dana TM4 Product installation guides for more details on installation and deinstallation procedure Change the faulty including safety warning considerations phase cable...
  • Page 139 Service Codes Switch ON the auxiliary batteries switch. Turn ignition ON. Perform a road test to check further occurrences of the original SysFile ID. Connect to the MCU with Does the same ODIN to check the SysFile ID occur Complete SysFile.

  • Page 140: Tt33

    Service Codes TT33 System Mode Referred by SysFile ID Condition Possible Causes Motor speed is too high - Torque derated but something else preventing The motor speed the speed to reduce. reached its limit in MCU speed setting parameters forward or backward Operational 0x3210 0x3211 wrongly configured (start, end and...
  • Page 141 Service Codes Note: Regarding the resolver angle waveform, 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.
  • Page 142 « Info – System missing intermittent signals power-up » evidences ? Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning Complete Defective MCU.
  • Page 143 Service Codes Switch OFF the auxiliary Refer to the Dana TM4 product batteries switch. installation guide for more details on installation and Defective Motor. deinstallation procedure Replace Motor. including safety warning Ensure all High Voltage considerations. Electrical sources are switched OFF.

  • Page 144: Tt34

    Service Codes TT34 System Mode Referred by SysFile ID Condition Possible Causes Phase current Defective MCU. Operational 0x3213 mismatch between 3 Defective motor. phases systems. Description The Troubleshooting Tree 34 indicates a phase To correctly diagnose the faulty system, connect the current mismatch between 3 phases systems.
  • Page 145 Service Codes...
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  • Page 149: Tt35

    Service Codes TT35 Condition Possible Causes System Mode Referred by SysFile ID The internal software No issue. Warning listed as an error if Operational 0x3303 process exceeded its reported at time 0:00:00 after power up. processing limit. MCU software error. Description The Troubleshooting Tree 35 indicates an error where To correctly diagnose the faulty system, connect the...
  • Page 150 Service Codes...

  • Page 151: Tt36

    The command did not match what was required by the CAN protocol. Note: Refer to the CAN protocol document as published on the Dana TM4 extranet site. To correctly diagnose the faulty system, connect the Diagnostic Tool (see «Diagnostics» section for test...
  • Page 152 Service Codes...

  • Page 153: Tt37

    CAN communications. The CAN network might cause the issue fixed. Refer to the CAN protocol document published on the Dana TM4 extranet site. The MCU itself may be defective. Note: Refer to the CAN protocol document as published on the Dana TM4 extranet site.
  • Page 154 Service Codes Connector type 1 and type 2 pinouts. Expected resistance measurement between CAN ports.
  • Page 155 Service Codes Refer to the CAN protocol Troubleshooting Tree 37 document as published on the Dana TM4 extranet site Does the Device communicating Set the CAN protocol Switch OFF the auxiliary with the MCU comply with the CAN of the device batteries switch.
  • Page 156 Connect to the MCU with ODIN to check the SysFile. Does the same Defective MCU. Complete SysFile ID occur again? Replace MCU. Refer to the Dana TM4 product installation guide for more details on installation and deinstallation procedure including safety warning considerations...

  • Page 157: Tt38

    Service Codes TT38 System Mode Referred by SysFile ID Condition Possible Causes Deactivation The VMU/ECU has sent a shutdown process couldn't be request to the MCU during operation, Operational 0x050B 0x050C successfully causing this error to be raised. executed. Defective MCU. Description The event category 38 indicates an error due to the To correctly diagnose the faulty system, connect the...
  • Page 158 Service Codes...

  • Page 159: Tt39

    Service Codes TT39 System Mode Referred by SysFile ID Condition Possible Causes This error is activated Some other error caused the SysFile to 0x0506 0x0507 0x0508 Operational by a lower level error. be raised. 0x0509 0x050A 0x050D Description The event category 39 shows a sequencer type error. These errors are caused by a lower level error type and refer to the errors raised under the same ‘’Info- System power-up’’.
  • Page 160 Service Codes...

  • Page 161: Tt40

    Service Codes TT40 System Mode Referred by SysFile ID Condition Possible Causes 1. This warning can potentially cause This warning is the 0X320D error to be raised. detected due to a 2. Abnormal transmission inconsistent Operational 0x3407 resolver hardware rotation load. abnormal signal.
  • Page 162 Service Codes Note: Regarding the resolver angle waveform, 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.
  • Page 163 Service Codes Troubleshooting Tree 40 Switch ON the auxiliary batteries switch. Turn ignition ON. Connect to the MCU with ODIN. Perform a road test to check further error occurrences of Access the BlackBox data under : the original event code. Diagnostic \ BlackBox \ View BlackBox Connect to the MCU with...
  • Page 164 Connector Integrity » interface connector ? Subtree (STT01) Refer to the Dana TM4 Product installation guide and operation and maintenance manual for more details on the Defective MCU. phase cables configurations and parameter setting...

  • Page 165: Stt01: Verify Connector Integrity

    Service Codes STT01: Verify Connector Integrity Related TT External input Possible Causes One pin is bent or broken causing conductivity fault and involved in several Troubleshooting Trees. Amphenol connector type: TT03 TT04 TT05 A pin might tend to move towards the inside of the motor on the TT28 TT29 TT31 None.
  • Page 166 Replace product. Can the (MCU or motor). connector broken ? locking mechanism Refer to the Dana TM4 Product installation be activated ? guide for more details on product connector pinout information Using a plier, gently try to Is there...

  • Page 167: Stt02: Verify Cooling Circuit Integrity

    Service Codes STT02: Verify Cooling Circuit Integrity Related TT External input Possible Causes The lack of coolant, the air within the motor an MCU lead to the system overheat. A slowdown cooling flow in the cooling circuit leads to the system TT21 TT22 TT23 TT24 overheat.
  • Page 168 Service Codes STT02 Bleed the cooling circuit from Is there air within any air. Refer to integration the cooling circuit ? vehicle installation manual. Is the cooling pump Investigate / correct the issue working correctly and with the cooling pump. Refer to provide enough integration vehicle installation coolant flow under normal...
  • Page 169 Service Codes Refer to the Dana TM4 product installation Note on cooling agent guide for more details on cooling agent mixture Wrong cooling agent can create dust / rust in the cooling circuit Purge the system of cooling agent Is the cooling...

  • Page 170: Appendix

    Appendix Appendix Appendix 1: Table of SysFile ID The following table of the SysFile ID gives the in formation of the diagnostic type, the code description and the related Troubleshooting Tree. SysFile Diagnostic Troubleshooting Description Type Tree SysFile 0x00 - SysFile cleared (The system file was 0x0000 Info cleared)
  • Page 171 Service Codes Diagnostic Troubleshooting SysFile Description Type Tree Board 0x2E - HVIL voltage output fault while in 0x032E Error standby state (Error HVIL voltage output fault while in standby state) Board 0x2F - HVIL internal fault while in operational 0x032F Warning state (Warning HVIL internal fault while in operational state)
  • Page 172 Appendix Diagnostic Troubleshooting SysFile Description Type Tree Sequencer 0x1C - Motor control in wrong state 0x051C Error (Wrong Motor control state for operational GEN) NvdGlobalSection (Error related 0x1000 Error NvdGlobalSection.) NvdGlobalSection (Error related 0x1001 Error NvdGlobalSection.) NvdGlobalSection (Error related Warning 0x1002 NvdGlobalSection.) NvdGlobalSection...
  • Page 173 Service Codes Diagnostic Troubleshooting SysFile Description Type Tree ParamMac 0x09 - Unsupported motor hardware 0x2209 Error version (Error related to hardware motor version stored in motor EEPROM) Motor Control Inverter 0x00 (Warning related to the 0x3100 Warning MotorControl) Motor Control Inverter 0x01 (Warning related to the Warning 0x3101 MotorControl)
  • Page 174 Appendix Diagnostic Troubleshooting SysFile Description Type Tree circuited) (Motor Back EMF reduction action initiated) Motor Control Machine 0x00 - MCU phase #1 0x3200 Error current reached the maximum (The MCU phase #1 current reached the maximum limit) Motor Control Machine 0x01 - MCU phase #2 0x3201 Error current reached the maximum (The MCU phase #2...
  • Page 175 Service Codes Diagnostic Troubleshooting SysFile Description Type Tree Motor Control Machine 0x13 - Phase current 0x3213 Error mismatch (Phase current mismatch) Application 0x00 (Error related to the general Error 0x3300 system) Application in Safe Mode (Problem with drive non- Error 0x3301 volatile data) 0x3302...
  • Page 176 Appendix Diagnostic Troubleshooting SysFile Description Type Tree ComClient 0x00 - No CAN mailbox are available for 0x4000 Error adapter (Error related communication protocol) ComClient 0x01 VmuCommandSafety TorqueCommand range 0x4001 Warning (VmuCommandSafety TorqueCommand is out of range) ComClient 0x02 VmuCommandSafety SpeedCommand range Warning 0x4002...
  • Page 177 Service Codes Diagnostic Troubleshooting SysFile Description Type Tree ComClient 0x0E - Safety check, delta too high between SpeedCommand (There is a significant 0x400E Warning difference SpeedCommand messages VmuCommand2 and VmuCommandSafety) ComClient 0x0F - Safety check, delta too high between TorqueCommand (There is a significant 0x400F Warning difference...
  • Page 178 Appendix Diagnostic Troubleshooting SysFile Description Type Tree ComClient 0x21 - VAUX data invalid (Auxiliary 0x4021 Warning voltage value is out of encoding range.) ComClient 0x22 - High power voltage data invalid 0x4022 Warning (High power voltage value is out of encoding range.) ComClient 0x23 - High power current data invalid 0x4023 Warning...
  • Page 179 Service Codes Diagnostic Troubleshooting SysFile Description Type Tree CAN RX: BMU2_1 timeout (Timeout occurred on 0x4122 Warning BMU2 message 1.) CAN RX: BMU3_1 timeout (Timeout occurred on Warning 0x4123 BMU3 message 1.) CAN RX: Invalid BMU source address (Received a Warning 0x4124 BMU message with unknown source address.)
  • Page 180 Appendix Diagnostic Troubleshooting SysFile Description Type Tree CAN RX: Maximum battery charge current is out of 0x4F09 Warning range (maximum battery charge current is out of range) CAN RX: A message received had the wrong DLC 0x4F0B Warning (One of the protocol message was received with the wrong DLC) CAN RX: Speed command status is invalid.

  • Page 181: Appendix 2: Table Of Troubleshooting Trees

    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 SysFile IDs Causes (numbered in order of likely occurrence) Tree 1.
  • Page 182 Troubleshooting SysFile IDs Causes (numbered in order of likely occurrence) Tree 1. 0x3113 warning occurred at the same time caused by another error 0x0319 while the vehicle was in high speed (Back EMF mechanism - phase short circuit protection engaged). 2.
  • Page 183 1. Motor not compatible with the MCU software. 0x120A 2. Third party motor not calibrated. 0x3212 3. Defective motor. 0x3302 1. Wrong motor type connected to the MCU. 0x2209 2. Wrong software flashed to the MCU. 0x3307 3. Defective Motor. 1.
  • Page 184 1. Air in the cooling circuit. 0x310F 2. Cooling liquid flow too low or nil (cooling pump issue). 0x3110 3. Cooling liquid temperature too high. 4. Wrong cooling agent mixture used – (can create dust/rust in the cooling circuit. 5. Defective MCU. 1.
  • Page 185 1. Short circuit between phases. 0x3200 2. The auxiliary vehicle battery not operating correctly. 0x3201 3. Intermittent or bad Vaux connection at the MCU. 0x3202 4. Vaux Fuse about to open or more resistive. 0x3204 5. 0x050B and/or 0x050C error occurred due to a VMU / ECU controller 0x3205 that sent a shutdown request CAN message while the motor speed 0x3206...
  • Page 186 1. Verify MCU CAN protocol document for protocol requirements. 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...
  • Page 187 0x4F12 0x4F21 0x4F22 0x4F23 0x4F24 0x4F25 0x4F2D 1. Verify MCU CAN protocol document for protocol requirements 0x4013 (controller issue). 0x4014 2. Defective CAN connection (Cable or harness). 0x4015 3. Defective CAN network. 0x4121 4. Defective MCU. 0x4122 0x4123 0x4124 0x4125 0x412D 0x4703 1.

  • Page 188: Appendix 3: Save Eeprom Sections

    Appendix Appendix 3: Save EEPROM Sections Power-on the unit with appropriate Vaux supply Open Odin Server 1 and establish connection to the MCU. Make sure that at the bottom left of the Odin screen, « Device Connected » is displayed in green text.

  • Page 189: Appendix 4: Retrieve Gdd Files And User Parameters

    Appendix Appendix 4: Retrieve GDD Files and User Parameters Power-on the unit with appropriate Auxiliary Vehicle Battery (Vaux) supply and IGNITION MCU input to high (Vaux level). Open Odin Server 1 and establish connection to the MCU. Make sure that at the bottom left of the Odin screen, «...

  • Page 190: Appendix 5: Cooling Agent Precautions

    Appendix Appendix 5: Cooling agent precautions Safety precaution Safety precaution WARNING In case of contact with eyes and skin, rinse with water and consult a doctor. • In case of ingestion, seek medical help It is mandatory to proceed with caution when connecting and disconnecting the system.

  • Page 191: Appendix 6: Update Software

    ODIN menu Package Files/ Workspaces. Download the up to date software from the 15. Contact TM4 Customer Service if you require help Dana TM4 extranet site. programming the system using TM4 ODIN. 2. Once downloaded, execute the software package exe file. The appropriate file will be saved at the right location on the PC for ODIN usage.
  • Page 192 For service assistance, call 1-877-777-5360 or visit our website at http://www.dana.com Dana TM4 Inc. 135, Joseph-Armand Bombardier, #25 Boucherville (Québec) J4B 8P1 Canada www.dana.com/TM4 The Application Engineering Department must approve all applications. Specifications and/or design are subject to change without notice or obligation.

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