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DANA SPICER PACCAR 220ev Troubleshooting Manual

Electrified chassis
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Table of Contents

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PACCAR
Troubleshooting Guide
ECTS-0300
October 2022
Models 220ev, K270e & K370e
DOC00015340
Electrified Chassis
®

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Summary of Contents for DANA SPICER PACCAR 220ev

  • Page 1 PACCAR Electrified Chassis ® Troubleshooting Guide ECTS-0300 October 2022 Models 220ev, K270e & K370e DOC00015340...
  • Page 2 Safety Warnings Safety Alerts and Warnings Safety Alerts Please read and follow all safety alerts in this guide. They are for your protection and information. The alerts can also help you avoid injury to yourself and your passengers. The alerts can also help prevent costly damage to the vehicle.

  • Page 3: Warnings And Safety Regulations

    Warning: Do not open the HV junction box Warning: Always use appropriate personal unless specifically instructed by this guide protective equipment (PPE) when working or by Dana. with the vehicle systems, even when the system is disconnected from a high voltage Warning: Before performing any source.
  • Page 4 For not touch any fluid on the vehicle. no reason should the electric powertrain be modified. Modification to any of Dana’s components 1. Contact firefighters. will void the warranty. Modifications to the electric chassis could cause death or personal injury.
  • Page 5 Refer to the LV system charging and jump components nearby welding could also be starting instructions for proper procedure. damaged. Dana’s warranty does not cover • It is preferred that 24V be provided across the 2 damage to components caused by any type LV batteries.
  • Page 6 LV battery charger. Fast charging a Note: Dana reserves the right to LV battery is dangerous and should only be attempted by a competent mechanic with discontinue or modify its models and/or the proper equipment.

  • Page 7: Table Of Contents

    Table of Contents Safety Alerts and Warnings ....2 How to Use This Guide ......... 17 ESS ............... 19 Safety Alerts ............ 2 Charging System ......... 161 Warnings and Safety Regulations ....3 Propulsion System ........270 Error Code Index ........8 Brake System ..........
  • Page 8 Error Code Index Error Code Index A/C Compressor no contact ........ 591 Fault Reason 0x23480A, 0x234907 ....378 Air Brake Compressor no contact ......406 Fault Reason 0x3cf8e3 ........379 Air Dryer No Contact ........... 411 Fault Reason 0x3df8ff ........380 Analog HVIL investigation ........

  • Page 9: Error Code Index

    Error Code Index F0008 Fault Reason 23 ..........41 Fault Reason 1 ..........418 Fault Reason 25 ..........42 Fault Reason 2 ..........422 Fault Reason 27 ..........43 Fault Reason 3 ..........423 Fault Reason 30 ..........44 Fault Reason 4 ..........426 Fault Reason 47 ..........
  • Page 10 Error Code Index F0040 ..............128 F0109 ..............683 F0041 ..............129 F0110 ..............684 F0042 ..............130 F0111 ..............550 F0043 ..............131 F0119 ..............140 F0044 ..............132 F0129 ..............143 F0045 ..............133 F0130 ..............628 F0046 ..............135 F0131 ..............
  • Page 11 Error Code Index OBC no contact ........... 266 Relay investigation ..........756 Override currently active ........669 Supervisory Controller no contact ....... 670 Power Steering no contact ........513 Telemetry No Contact OR Fleet owner is receiving Powertrain cooling pump No contact ....685 empty telemetry data files .......

  • Page 12: General Information

    General Information General Information PACCAR vehicle Diagnostics The Vehicle Control Unit (VCU) provides self- The PACCAR vehicle is driven by an electric diagnosis during operation. If the system detects a powertrain. High voltage batteries supply all onboard problem, it will display an error message on the systems.

  • Page 13: Vehicle System Overview

    General Information Vehicle System Overview This section provides a brief overview of the main Power Steering System … page 480 systems on the vehicle. More detailed information is The power steering system is an electro-hydraulic provided in the specific section for each system, system which produces supplemental steering force which can be found on the page indicated.

  • Page 14: Diagnostics

    HMI until the vehicle is reset by turning the ignition off and on. Some latching faults Refer to Dana's Diagnostic Guide for more may require a component service tool to reset the information on HMI screen operation and error code fault.

  • Page 15: Multimeter

    Diagnostics Multimeter Based upon electrical schematics and aided by component-specific error messages, a multimeter can be used to check sensor and solenoid resistances and to find wiring harness faults. The multimeter can be used to check: Continuity • Ground • •...

  • Page 16: Troubleshooting Tips

    If needed, further investigation therefore, it is always required to recheck the initial will be undertaken at the request of Dana experts. troubleshooting tree after having switched to If the problem can be traced to a continuity failure, another tree.

  • Page 17: Troubleshooting

    Diagnostics Troubleshooting How to Use This Guide To troubleshoot an error, locate the error code in this Each system section describes the main guide. components of the system. It is recommended to familiarize yourself with this material before The error codes are grouped by system. If you are beginning to troubleshoot.
  • Page 18 Troubleshooting Troubleshooting Tree Legend Within the troubleshooting trees, different shapes denote different types of actions: Indicates the beginning or end of a troubleshooting Start & End procedure. Indicates a troubleshooting action to be performed Action by the technician. Indicates a decision point between two paths in the Decision tree.

  • Page 19: Ess

    Troubleshooting The Energy Storage System (ESS) is the vehicle battery packs. It is one of three coolant loops on the battery pack. It includes the Battery Management vehicle along with the cooling system and the heater. System (BMS) and heating and cooling circuits to help maintain the proper operating temperature in Chiller cold weather.
  • Page 20 Troubleshooting F0016 - High Voltage system fault, Vehicle set to neutral Error Description Possible Causes Possible Solutions The VCU has lost communication 1) Defective MPDM relay K1. 1) Replace MPDM relay K1. with the BMS. 2) Defective MPDM relay K6. 2) Replace MPDM relay K6.
  • Page 21 Troubleshooting Connector C93S (socket) Connector C53 Connector C76 Connector C367P (pin) Connector C93P (pin) Connector C367S (socket)
  • Page 22 Troubleshooting HMI displays or logs Fault code F0016 Refer to CAN investigation subtree Investigate CAN A and CAN C network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN A or C actions prescribed in the displayed? network?
  • Page 23 Troubleshooting Continued from previous page Does the HMI also Refer to error F0058 display F0058? troubleshooting tree. Does the HMI also Refer to error F0147 display F0147? troubleshooting tree. Does the HMI also Refer to error F0051 display F0051? troubleshooting tree. Does the HMI also Refer to error F0052 display F0052?
  • Page 24 Troubleshooting Continued from previous page Disconnect connector C11 from MPDM. Disconnect connector C93, C40, C76, C367, C50, C53. Disconnect connector C44 from S-Box. Refer to connector investigation subtree. Is there any Defective connector. problem with the Replace the connector as described in the “Wire connector Harness Connector Identification, Location, and integrity?
  • Page 25 Continued from previous page Is there any evidence Defective harness. of a continuity loss? Replace harness. Defective supervisory controller. Replace supervisory controller. Is the error still occurring on further Contact Dana for further key ON or charge investigation. cycles? Complete...
  • Page 26 Troubleshooting F0017 - High Voltage system fault, Service vehicle soon Error Description Possible Causes Possible Solutions VCU has detected that precharge 1) No contact with DCDC. 1) Troubleshoot specific error. failed. 2) CAN communication problem. 2) Resolve CAN communication problem. 3) Blown HV fuse F8.
  • Page 27 Inspect HV fuse F8 in the HV defined in the Service Manual junction box. and Diagnostic Guide. Replace fuse HV F8 and Is fuse HV F8 blown or contact DANA for intermittent? investigation on the cause of the blown fuse. Contact Dana for further investigation.
  • Page 28 Troubleshooting F0018 - High Voltage system fault, Service vehicle soon Error Description Possible Causes Possible Solutions Precharge failed over 3 times. 1) No contact with DCDC. 1) Troubleshoot specific error. 2) CAN communication problem. 2) Resolve CAN communication problem. 3) Blown HV fuse F8. 3) Replace HV fuse F8.
  • Page 29 Troubleshooting HMI displays or logs Fault code F0018 Does the HMI also display Refer to the DCDC No contact “DCDC No contact”? troubleshooting tree. Refer to CAN investigation subtree Investigate CAN A and CAN D networks. Is there still a precharge Was there a defect on CAN error on further truck Complete...
  • Page 30 Inspect HV fuse F8 in the HV junction box. Replace fuse F8 and contact Is fuse F8 blown or DANA for investigation on the intermittent? cause of the blown fuse. Cycle the key in order to be able to retry the pre-charge cycle, in order to see if the problem is solved.
  • Page 31 Troubleshooting F0019 (Fault Reason 1, 4, 10, 13) Error Description Possible Causes Possible Solutions This error indicates that the 1) Battery TMS internal failure. 1) Replace Battery TMS. Battery TMS has detected an internal failure. HMI displays or logs Fault code F0019 and TMS fault reason 1/4/10/13 Defective Battery TMS.
  • Page 32 Troubleshooting F0019 (Fault Reason 32) Error Description Possible Causes Possible Solutions Battery TMS has detected a 1) ESS fault. 1) Troubleshoot specific error. precharge failure. 2) Battery TMS internal failure. 2) Replace Battery TMS. The precharge circuit manages the voltage ramp-up Precharge errors may also to be raised by the BMS of the HV system upon startup of the vehicle.
  • Page 33 Troubleshooting F0019 (Fault Reason 34) Error Description Possible Causes Possible Solutions Battery TMS has detected an input 1) ESS fault. 1) Troubleshoot specific error. overvoltage, overcurrent, or internal DC-DC converter failure. 2) Loss of continuity due to 2) Replace HV harness. defective HV connector or harness.
  • Page 34 Does the HMI also display Refer to the corresponding HV DC bus raising an F0026? error troubleshooting tree. overvoltage error? Contact Dana for further investigation. WARNING: Electrical hazard. Follow Safety Warnings and High With a multimeter, check for continuity between the Voltage Shutdown Procedures...
  • Page 35 Troubleshooting F0019 (Fault Reason 48) Error Description Possible Causes Possible Solutions Battery TMS has lost 1) No contact with BMS. 1) Troubleshoot specific error. communication with the BMS. 2) CAN communication problem. 2) Resolve CAN communication problem. 3) Battery TMS internal failure. 3) Replace Battery TMS.
  • Page 36 Troubleshooting F0019 (Fault Reason 49) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0019 and TMS fault reason 49 Defective Battery TMS.
  • Page 37 Troubleshooting F0020 (Fault Reason 2, 5, 11, 14) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 2/5/11/14 Defective Battery TMS.
  • Page 38 Troubleshooting F0020 (Fault Reason 19) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 19 Defective Battery TMS.
  • Page 39 Troubleshooting F0020 (Fault Reason 21) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 21 Defective Battery TMS.
  • Page 40 Troubleshooting F0020 (Fault Reason 22) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 22 Defective Battery TMS.
  • Page 41 Troubleshooting F0020 (Fault Reason 23) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 23 Defective Battery TMS.
  • Page 42 Troubleshooting F0020 (Fault Reason 25) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 25 Defective Battery TMS.
  • Page 43 Troubleshooting F0020 (Fault Reason 27) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 27 Defective Battery TMS.
  • Page 44 Troubleshooting F0020 (Fault Reason 30) Error Description Possible Causes Possible Solutions TMS has reported a low fluid level 1) Leak in ESS cooling system. 1) Resolve leak in ESS cooling in the coolant reservoir. system. 2) Loss of continuity between chiller and coolant level sensor 2) Replace LV connector or due to defective LV connector...
  • Page 45 Troubleshooting HMI displays or logs Fault code F0020 and TMS fault reason 30 For safety reasons, make sure that the truck is parked Turn OFF ignition. outside when this occurs. Wait 8 hours for the batteries Turn ignition ON. and coolant to cool down. Check the chiller tank liquid level with the reservoir cap open.
  • Page 46 Open the ESS cover panel in order to check for potential leaks in the ESS cooling circuit inside the ESS. Replace faulty cooling hoses Are there any leaks in the according to the service ESS cooling circuit? manual instructions. Contact Dana for further investigation.
  • Page 47 Troubleshooting Disconnect connector C39 from chiller tank. Refer to connector integrity Disconnect connector C40. inspection subtree. Disconnect connector C46 from Battery TMS. Defective connector. Is there Replace the connector as described in the “Wire any problem with Harness Connector Identification, Location, and the connector Service Chart”...
  • Page 48 Troubleshooting F0020 (Fault Reason 47) Error Description Possible Causes Possible Solutions TMS has detected an overvoltage 1) DCDC or LV distribution fault. 1) Troubleshoot specific error. or undervoltage on its LV power supply. 2) Blown MPDM fuse F3. 2) Replace MPDM fuse F3. 3) Defective MPDM relay K7.
  • Page 49 Troubleshooting HMI displays or logs Fault code F0020 and TMS fault reason 47 Does the HMI also display Refer to the corresponding F0008 or F0095? troubleshooting tree. Does the HMI also Refer to the F0086 display F0086? troubleshooting tree. Does the HMI also Refer to the F0066 display F0066? troubleshooting tree.
  • Page 50 Troubleshooting Continued from previous page Refer to the connector integrity investigation subtree. Is there Defective connector. any problem with Replace the connector as described in the “Wire the connector Harness Connector Identification, Location, and integrity? Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: 24V fuse box C20...
  • Page 51 -Inspect all connectors and wires between the two test points of the harness ends. Did fuse F1 blow Replace fuse F1 on 24V fuse box Complete again during test C20. drive? Restart the vehicle. Contact Dana for further investigation.
  • Page 52 Troubleshooting F0020 (Fault Reason 50) Error Description Possible Causes Possible Solutions Battery TMS has detected an 1) Battery TMS internal failure. 1) Replace Battery TMS. internal failure of the Battery TMS. HMI displays or logs Fault code F0020 and TMS fault reason 50 Defective Battery TMS.
  • Page 53 Troubleshooting F0020 (Fault Reason 51) Error Description Possible Causes Possible Solutions TMS has detected a loss of power 1) ESS fault. 1) Troubleshoot specific error. to its internal DC-DC converter. 2) Loss of continuity due to 2) Replace HV harness. defective HV connector or harness.
  • Page 54 Does the HMI also display Refer to the corresponding HV DC bus raising an F0026? error troubleshooting tree. overvoltage error? Contact Dana for further investigation. WARNING: Electrical hazard. With a multimeter, check for continuity between the following points: Follow Safety Warnings and High...
  • Page 55 Use may be a software or VCU error and the technician extreme caution and report all instances of should contact Dana for further investigation. this error to Dana. HMI displays or logs Fault code F0022...
  • Page 56 This error is expected to be accompanied by error F0026 BMS fault reasons, the technician should F0026 which provides a BMS fault reason code contact Dana for further investigation. indicating the specific reason the limitation was HMI displays or logs...
  • Page 57 F0026 BMS fault reasons and the ESS SOC is not braking power to be limited to 25% in response to close to 100%, the technician should contact Dana fault reason 52, 54, 56, 58, 60, 62, 64, 66, 68, or 70, for further investigation.
  • Page 58 This error is expected to be accompanied by error F0026 BMS fault reasons and the ESS SOC is not F0026 which provides a BMS fault reason code close to 100%, the technician should contact Dana indicating the specific reason the limitation was for further investigation.
  • Page 59 Troubleshooting F0026 (Fault Reason 1, 2, 3) Error Description Possible Causes Possible Solutions BMS has detected an overvoltage 1) Temporary overvoltage or 1) Allow ESS to rest or discharge in one or more cells. voltage imbalance. and recharge ESS. Fault reasons 1, 2, and 3 are numbered in order of It may be possible to resolve a moderate overvoltage increasing severity.
  • Page 60 Troubleshooting Continued from previous page Is the maximum Contact Dana for further cell voltage over investigation. 3.7V? Turn ON the defrost for 2 hours until the message has disappeared. Turn OFF defrost. Plug in a level 2 AC charger and fully charge the truck.
  • Page 61 Troubleshooting F0026 (Fault Reason 4, 5, 6) Error Description Possible Causes Possible Solutions BMS has detected an 1) Temporary undervoltage or 1) Allow ESS to rest, then undervoltage in one or more cells. voltage imbalance. change vehicle to 100%. Fault reasons 4, 5, and 6 are numbered in order of Note: For best ESS performance and increasing severity.
  • Page 62 Plug in EVSE and charge to minimum cell voltage in the displayed on the HMI? 100%. ESS diagnostic page. Is the minimum cell Contact Dana for further voltage under 2.3 V? investigation. Is the lowest cell voltage Use service procedure for under 2.5 V? overriding safety controller.
  • Page 63 This error indicates that the BMS has detected an extreme undervoltage (less than 1 V) in one or more This error must be referred to Dana for specialized cells. The BMS will request the vehicle to shut down troubleshooting.
  • Page 64 Troubleshooting F0026 (Fault Reason 8, 9, 10) Error Description Possible Causes Possible Solutions BMS has detected that the ESS 1) Cell overvoltage. 1) Troubleshoot specific error. voltage is too high. 2) Temporary pack overvoltage. 2) Allow ESS to rest or discharge and recharge ESS.
  • Page 65 Troubleshooting HMI displays or logs Fault code F0026 and BMS fault reason 8/9/10 Unplug EVSE from the truck if applicable. Turn ignition OFF and switch OFF LOTO switch. Wait one hour before taking any further action. Turn the truck back ON in accessory mode.
  • Page 66 Troubleshooting Continued from previous page Is the highest pack Contact Dana for further voltage over 710 V? investigation. Turn ON the defrost for 2 hours until the message has disappeared. Turn OFF defrost. Check the ESS diagnostic page on the HMI.
  • Page 67 Troubleshooting F0026 (Fault Reason 11, 12, 13) Error Description Possible Causes Possible Solutions BMS has detected that the ESS 1) Temporary pack undervoltage. 1) Allow ESS to rest, then voltage is too low. change vehicle to 100%. Note: Make sure HV systems are not in use Fault reasons 11, 12, and 13 are numbered in order of increasing severity.
  • Page 68 ESS diagnostic page. HMI? Plug in EVSE and charge to 100%. Is the lowest pack Contact Dana for further voltage under investigation. 441.6 V? Is the lowest pack Use service procedure for voltage between overriding safety controller.
  • Page 69 Troubleshooting F0026 (Fault Reason 14, 15, 16) Error Description Possible Causes Possible Solutions BMS has detected that the 1) Chiller fault. 1) Troubleshoot specific error. temperature in one or more cells is too high. 2) Leak or low coolant in ESS 2) Repair leak and/or refill cooling system.
  • Page 70 Troubleshooting HMI displays or logs Fault code F0026 and BMS fault reason 14/15/16 For safety measure make sure that the truck is parked Wait 8 hours for the batteries Turn OFF ignition. outside under shade when cells to cooldown. this occurs. Check that the pack has cooled to Turn ignition ON.
  • Page 71 Troubleshooting Continued from previous page Refer to the CAN investigation subtree. Investigate CAN A and CAN B networks. Was a problem found Repair according to the with either CAN A or actions prescribed in the CAN B network? subtree. Is the error persisting? Wait for the cooling liquid to cool down and check the chiller tank liquid level with...
  • Page 72 Open the ESS cover panel in order to check for potential leaks in the ESS cooling circuit inside the ESS. Replace the faulty cooling Is there any leak in the pipes following the ESS cooling circuit? maintenance manual instructions. Contact Dana for further investigation.
  • Page 73 Troubleshooting Disconnect connector C39 from chiller tank. Refer to connector investigation Disconnect connector C40 from Cradle. subtree. Disconnect connector C46 from chiller Defective connector. Is there any Replace the connector as described in the “Wire problem with the Harness Connector Identification, Location, and connector Service Chart”...
  • Page 74 HV batteries do not function below -35°C. Move the vehicle to a location Does the fault code where ambient temperature is Complete reappear? above 0°C. Allow batteries to warm to greater than -25°C. Does the fault code Contact DANA for reappear? further investigation. Complete...
  • Page 75 Troubleshooting F0026 (Fault Reason 18, 19, 20) Error Description Possible Causes Possible Solutions BMS has detected that the 1) Temporary cell 1) Allow ESS to cool down. temperature difference between overtemperature. two cells in the ESS is too large. This error indicates that the BMS has detected that This error is likely to appear along with Error F0026 the temperature difference between two cells in the (BMS fault reason 14, 15, 16) indicating that the...
  • Page 76 Refer to F0020 TMS 30 F0020 TMS 30? troubleshooting tree. Turn OFF ignition. Wait 8 hours for the batteries’ cells to cooldown. Turn ignition ON. Is the error is still being Contact Dana for further displayed on the HMI investigation. intermittently? Complete...
  • Page 77 Warning: HV system isolation fault can pose an extreme hazard and may result in high voltage being present in parts of the vehicle that are not normally energized. Use extreme caution and report all instances of this error to Dana. Connector C717 (green)
  • Page 78 F0022, transporting a heavy F0035, F0036, F0037 or load uphill? F0051 Reason 14? Contact Dana for further investigation. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 79 50% power. If overcurrent. fault reason 26 or 27 is raised, regenerative braking will be disabled. Contact Dana if this fault code occurs. HMI displays or logs Fault code F0026 and BMS fault reason 25/26/27 Contact Dana for further investigation.
  • Page 80 Charging will be terminated. The vehicle will not be able to restart until the error is resolved. HMI displays or logs Fault code F0026 and BMS fault reason 28 Contact Dana for further investigation.
  • Page 81 If this error is raised, the BMS will request the vehicle to shut down and charging will be terminated. The vehicle will not be able to restart until the error is resolved. HMI displays or logs Fault code F0026 and BMS fault reason 29 Contact Dana for further investigation.
  • Page 82 Troubleshooting F0026 (Fault Reason 30) Error Description Possible Causes Possible Solutions BMS has detected that the 1) Cell overvoltage or 1) Troubleshoot specific error. difference in state of charge (SOC) undervoltage. between cells in the ESS is too 2) Allow ESS to rest, then large.
  • Page 83 Turn ignition OFF and switch any further action. OFF LOTO switch. Turn ON LOTO Switch Plug in only a level 2 AC charger. Charge vehicle until charge cycle automatically ends. Is the fault code Complete still present? Contact Dana for further investigation.
  • Page 84 Troubleshooting F0026 (Fault Reason 32, 33, 34) Error Description Possible Causes Possible Solutions BMS has detected that the state of 1) Low SOC. 1) Charge the vehicle. charge (SOC) of the ESS is low. 2) Temporary SOC imbalance. 2) Allow ESS to rest, then change vehicle to 100%.
  • Page 85 Charge vehicle until charge ESS diagnostic page. cycle automatically ends. Is the minimum cell Contact Dana for further voltage under 2.3 V? investigation. Is the lowest cell Use service procedure for voltage under 2.5 V? overriding safety controller.
  • Page 86 Troubleshooting F0026 (Fault Reason 35) Error Description Possible Causes Possible Solutions BMS detects a BTMS fault or 1) TMS fault. 1) Troubleshoot specific error. abnormal ESS coolant temperature. 2) Leak, blockage, or flow 2) Repair leak, blockage, or flow reduction in ESS cooling reduction.
  • Page 87 Troubleshooting HMI displays or logs Fault code F0026 and BMS fault reason 35 Does the HMI also Refer to corresponding error display any Battery troubleshooting tree. TMS related error? Does the HMI also Refer to error F0026 BMS 44 display F0026 troubleshooting tree.
  • Page 88 Inspect the rest of the ESS cooling circuit for leaks, clogs or possible flow reduction. Is there any evidence Repair the defect as per of a defect causing a the maintenance manual cooling reduction? instructions. Contact Dana for further investigation.
  • Page 89 Troubleshooting F0026 (Fault Reason 36) Error Description Possible Causes Possible Solutions BMS has detected an abnormal 1) Defective harness between S- 1) Replace harness. heating rate in the ESS heating Box and battery pack(s). circuit. The heating circuit is powered from the S-Box and If the defect is inside one of the battery packs, the runs through each ESS battery pack.
  • Page 90 Troubleshooting Disconnect connector C782 & C787 from S-Box. Disconnect connector C783 & C784 from pack 2. Disconnect connector C785 & C786 from pack 1. **All heater cables must be disconnected from the S-Box for these tests.** Refer to connector investigation subtree.
  • Page 91 Troubleshooting Continued from previous page Is there any evidence of a Contact Dana for further defect between the pins of investigation. the packs? With a multimeter, check for continuity between the following points on the HV wiring: S-Box C787P Pack 1 C786P...
  • Page 92 Troubleshooting Disconnect connectors C769, C765, C762 & C772 from S-Box. Disconnect connectors C768 & C771 from pack 1. Disconnect connectors C766 & C767 from pack 2. Disconnect connectors C764 & C761 from pack 3. Disconnect connectors C770 & C763 from pack 4. **All heater cables must be disconnected from the S-Box for these tests.** Refer to connector investigation...
  • Page 93 Troubleshooting Continued from previous page Is there any evidence of a Contact Dana for further defect between the pins of investigation. the packs? With a multimeter, check for continuity between the following points on the HV wiring: S-Box C772P Pack 1 C771P...
  • Page 94 BMS fault reason 37 For safety measure make sure that the truck is parked outside when this occurs. Does the HMI also Refer to corresponding error display any BMS troubleshooting tree. related error? Contact Dana as soon as possible for further investigation.
  • Page 95 The vehicle is then enabled to start. If the BMS F0026 (BMS Fault Reason 38) appears without detects a problem during this process, precharge will F0017 or F0018, contact Dana for further be flagged as failed and the vehicle startup will be investigation.
  • Page 96 1) ESS internal failure. 1) Contact Dana. failure which requires support from Dana. If this error is raised, the vehicle will not be able to start. HMI displays or logs Fault code F0026 and BMS fault reason 39 Contact Dana for further investigation.
  • Page 97 F0036, F0037, or F0038) are expected to appear. If F0026 (BMS Fault Reason 40, 41, 42, or 43) If fault reason 40 is raised, the high voltage power appears alone, the technician should contact Dana and regenerative braking power will both be limited for further investigation.
  • Page 98 Always report any instance of vehicle? these faults to DANA. Turn on ignition Contact Dana for further investigation. Has the error been cleared? Reconnect vehicle to EVSE and charge vehicle. Contact Dana for further investigation. Complete Possible error occurrence Contact DANA about this problem...
  • Page 99 Investigate CAN A network. Could you find a Repair according to the problem with the CAN A actions prescribed in the network? subtree. Is the error still being Contact Dana for further raised on further key ON investigation. cycles? Complete...
  • Page 100 Charging will be terminated. The vehicle will not be able to restart until the error is cleared. HMI displays or logs Fault code F0026 and BMS fault reason 45 Contact Dana for further investigation.
  • Page 101 BMS has detected an ESS internal 1) ESS internal failure. 1) Contact Dana. failure which requires support from Dana. If this error is raised, charging will be terminated. HMI displays or logs Fault code F0026 and BMS fault reason 46 Contact Dana for further investigation.
  • Page 102 Troubleshooting F0026 (Fault Reason 47) Error Description Possible Causes Possible Solutions BMS has detected that one or 1) MSD or HV connector 1) Connect MSD or HV more of the battery packs is disconnected from S-Box. connector. disconnected from the S-Box. 2) Loss of continuity due to 2) Replace HV harness or MSD.
  • Page 103 Troubleshooting HMI displays or logs Fault code F0026 and BMS fault reason 47 WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Disconnect MSD(s) from the S-Box. Inspect the HV connectors on the S-box.
  • Page 104 Continued from previous page Defective MSD. Is there any evidence of a Replace MSD. continuity loss? Inform DANA before restarting the truck. Disconnect connectors C718, C719, C716 and C717 from the S-Box. Refer to connector investigation subtree. Was a defect found in the Defective harness.
  • Page 105 Troubleshooting F0026 (Fault Reason 48) Error Description Possible Causes Possible Solutions BMS has detected a discontinuity 1) HV connector disconnected 1) Connect HV connector. in the ESS internal HVIL. from S-Box. 2) Replace HV harness. 2) Loss of continuity due to defective HV connector.
  • Page 106 Service Manual and Diagnostic Guide. Disconnect connectors C718, C719, C716 and C717 from the S-Box. Refer to connector investigation subtree. Was a defect found in the Defective harness. high voltage connectors? Replace harness. Contact Dana for further investigation.
  • Page 107 HMI displays or logs Fault code F0026 and BMS fault reason 49, 50, 51, 52, 53, 54 , 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70 Contact Dana for further investigation.
  • Page 108 1) ESS internal failure. 1) Contact Dana. failure which requires support from Dana. If this error is raised during charging, charging will be terminated. HMI displays or logs Fault code F0026 and BMS fault reason 71 Contact Dana for further investigation.
  • Page 109 Unplug and use level 2 being use to charge charger. the vehicle? Unplug the EVSE from the truck normally. Restart the charge with a level 2 EVSE. Is the error still being Contact Dana for further raised on further charge investigation. cycles? Complete...
  • Page 110 Fault code F0026 and BMS fault reason 74 Remove power from EVSE. Unplug the EVSE from the truck normally. Restart the charge with another level 2 EVSE. Is the error still being raised on further charge Complete cycles? Contact Dana for further investigation.
  • Page 111 1) S-Box internal failure or 1) Contact Dana. vehicle architecture. If they software error. appear, please contact Dana for further investigation. If fault reason 75 or 77 is raised, charging will be terminated. If fault reason 76 is raised, charging power will be limited to 50%.
  • Page 112 Possible Causes Possible Solutions BMS has detected an ESS internal 1) ESS internal failure. 1) Contact Dana. failure which requires support from Dana. HMI displays or logs Fault code F0026 and BMS fault reason 78 Contact Dana for further investigation.
  • Page 113 Troubleshooting F0026 (Fault Reason 100) Error Description Possible Causes Possible Solutions BMS has detected a voltage 1) Temporary voltage imbalance. 1) Allow ESS to rest, then imbalance between two or more change vehicle to 100%. cells in the ESS. Note: For best ESS performance and This error may be accompanied by a cell overvoltage (BMS Fault Reason 1, 2, 3) or cell undervoltage vehicle range HV batteries must regularly be...
  • Page 114 OFF LOTO switch. Turn the truck back on in accessory mode. Plug in only a level 2 AC charger. Charge vehicle until charge cycle automatically ends. Is the error message still Complete displayed on the HMI? Contact Dana for further investigation.
  • Page 115 If fault reason 102 is raised, regenerative braking power will be limited to 50%. If fault reason 103 or 104 is raised, regenerative braking will be disabled. HMI displays or logs Fault code F0026 and BMS fault reason 102/103/104 Contact Dana for further investigation.
  • Page 116 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request driving to be disabled in response to fault reason 5, 6, 7, 12, 13, 15, 16, 29, 37, 41, or 42.
  • Page 117 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the high voltage power to be limited to 50% in response to fault reason 4, 11, 14, 22, 23, 24, 32, 33, 34, or 40.
  • Page 118 F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the vehicle to shut down in response to fault reason 6, 7, 13, 29, 37, or...
  • Page 119 This error is expected to be accompanied by error If error F0030 appears without F0026 (BMS fault F0026 which provides a BMS fault reason code reason 16), the technician should contact Dana for indicating the specific reason the limitation was further investigation.
  • Page 120 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request regenerative braking to be disabled in response to fault reason 1, 2, 3, 7, 9, 10, 15, 16, 26, 27, 28, 29, 37, 41, 42, 44, 45, 47, 48, 103, or 104.
  • Page 121 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the regenerative braking power to be limited to 25% in response to fault reason 52, 54, 56, 58, 60, 62, 64, 66, 68, or 70.
  • Page 122 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the regenerative braking power to be limited to 50% in response to fault reason 8, 14, 25, 40, or 102.
  • Page 123 F0026 (BMS fault extreme caution and report all instances of reason 40, 41, 42, or 43) if there is a HV system this error to Dana. HMI displays or logs Fault code F0035 Is F0026 BMS 40...
  • Page 124 F0026 (BMS fault extreme caution and report all instances of reason 40, 41, 42, or 43) if there is a HV system this error to Dana. HMI displays or logs Fault code F0036 Is F0026 BMS 41...
  • Page 125 F0026 (BMS fault extreme caution and report all instances of reason 40, 41, 42, or 43) if there is a HV system this error to Dana. HMI displays or logs Fault code F0037 Is F0026 BMS 42...
  • Page 126 The BMS independently monitors isolation extreme caution and report all instances of resistance and will raise error F0026 (BMS fault this error to Dana. reason 40, 41, 42, or 43) if there is a HV system isolation fault condition detected. VCU and BMS fault code may both appear for the same problem.
  • Page 127 Is F0119 also Refer to error F0119 present? troubleshooting tree. Stop the charge and wait for the ESS to cooldown. Start the charge again Is the error still being Contact Dana for further raised on further charge investigation. cycles? Complete...
  • Page 128 This error is expected to be accompanied by error If error F0040 appears without F0026 (BMS fault F0026 which provides a BMS fault reason code reason 47), the technician should contact Dana for indicating the specific reason the limitation was further investigation.
  • Page 129 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will terminate the charging process and open the charging relay in response to fault reason 7 or 37.
  • Page 130 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will terminate the charging process in response to fault reason 1, 2, 3, 8, 9, 10,...
  • Page 131 If error F0043 appears without one of the listed able to start again after shutdown. F0026 BMS fault reasons, the technician should contact Dana for further investigation. This error is expected to be accompanied by error F0026 which provides a BMS fault reason code indicating the specific reason the limitation was requested.
  • Page 132 7. If error F0044 appears without one of the listed F0026 BMS fault reasons, the technician should contact Dana for further investigation. HMI displays or logs Fault code F0044 Is F0026 BMS 7...
  • Page 133 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the ESS cooling system to shut off in response to fault reason 35.
  • Page 134 Inspect the rest of the ESS cooling circuit for leaks, clogs or possible flow reduction. Is there any evidence Repair the defect as per the of a defect causing a maintenance manual cooling reduction ? instructions. Contact Dana for further investigation.
  • Page 135 F0026 which provides a BMS fault reason code F0026 BMS fault reasons, the technician should indicating the specific reason the limitation was contact Dana for further investigation. requested. The BMS will request the ESS heating circuit to shut off in response to fault reason 36, 49, or 50.
  • Page 136 ESS is above a F0026 (BMS fault reason 1, 2, or 3). If error F0047 critical threshold. The vehicle is requested to shut appears alone, the technician should contact Dana down. for further investigation.
  • Page 137 F0026 (BMS fault reason 14, 15, or 16). If error critical threshold. The vehicle is requested to shut F0048 appears alone, the technician should contact down. Dana for further investigation. HMI displays or logs Fault code F0048 Is F0026 BMS 14/15/16...
  • Page 138 ESS is below a F0026 (BMS fault reason 4, 5, or 6). If error F0049 critical threshold. The vehicle is requested to shut appears alone, the technician should contact Dana down. for further investigation.
  • Page 139 1) Troubleshoot specific error. management error. F0026 (BMS fault reason 35) should also be raised. Troubleshooting for this error is the same as for If not, the technician should contact Dana for further F0026 (BMS fault reason 35). investigation. HMI displays or logs...
  • Page 140 Troubleshooting F0119 - Check battery Chiller Coolant level / Sensor Error Description Possible Causes Possible Solutions Chiller has reported a low coolant 1) Leak in ESS cooling system. 1) Resolve leak in ESS cooling level in the ESS cooling system. system.
  • Page 141 Troubleshooting HMI displays or logs Fault code F0119 Turn ignition OFF Wait for the cooling liquid to cool down and check the chiller tank liquid level Is the chiller tank liquid level low ? Check the chiller tank for potential leaks Replace the cooling tank Is there any leaks in the following the maintenance...
  • Page 142 Troubleshooting Disconnect connector C39 from chiller tank. Refer to connector investigation Disconnect connector C40. subtree. Diconnect connector C46 from chiller Defective connector. Is there any Replace the connector as described in the “Wire problem with the Harness Connector Identification, Location, and connector Service Chart”...
  • Page 143 This error is expected to be accompanied by F0026 (BMS fault reason 30). If not, the technician should connect the vehicle to a charger, a level 2 contact Dana for further investigation. charger is required. Error F0026 (BMS fault reason 1, 2, 3, 4, 5, 6, 8, 9,...
  • Page 144 OFF LOTO switch. Turn the truck back on in accessory mode. Plug in only a level 2 AC charger. Charge vehicle until charge cycle automatically ends. Is the fault code Complete still present? Contact Dana for further investigation.
  • Page 145 Troubleshooting F0146 - Potential High Voltage Hazard! Chiller HVIL Fault Error Description Possible Causes Possible Solutions The chiller has detected a 1) HV connector unplugged. 1) Plug in HV connector. discontinuity in the high voltage interlock loop (HVIL). 2) Defective HV connector or 2) Replace HV harness.
  • Page 146 Cradle C724S Tank C724S Connector pin Connector pin Pin 3 Pin 4 - Continuity : Resistance is less than or equal to 2ohms. Contact Dana for further Is there any evidence of Defective harness. investigation. a continuity loss ? Replace harness.
  • Page 147 Troubleshooting F0153 - Battery Balance Error. Please charge battery to 100% Error Description Possible Causes Possible Solutions VCU has detected a voltage 1) ESS fault. 1) Troubleshoot specific error. imbalance between the ESS battery packs 2) Temporary SOC imbalance. 2) Recharge ESS to 100% SOC. This error may be accompanied by error F0026 cycle when HV batteries are charged to (BMS fault reason 1, 2, 3, 4, 5, or 6).
  • Page 148 Troubleshooting F0154 - Battery Maintenance. Please Charge battery to 100% Error Description Possible Causes Possible Solutions VCU has detected that the state of 1) Temporary BMS error. 1) Recharge ESS to 100% SOC. charge (SOC) reported by the BMS is implausibly low. The VCU compares the SOC reported by the BMS to calculated valued that drifts over time.
  • Page 149 Troubleshooting F0155 - Driving Range Significantly Reduced. Please charge battery to 100% Error Description Possible Causes Possible Solutions VCU has detected that the state of 1) Temporary BMS error. 1) Recharge ESS to 100% SOC. charge (SOC) reported by the BMS is implausibly high.

  • Page 150: Bms No Contact

    Troubleshooting BMS no contact Error Description Possible Causes Possible Solutions The VCU has not received any 1) Blown fuse or defective relay 1) Replace defective fuse or CAN message from the BMS in MPDM. relay. within a specified time interval. 2) Blown 12V fuse F19.
  • Page 151 Troubleshooting Connector C44 Connector C54 Connector C50 Connector C75 Connector C53 Connector C76...
  • Page 152 Troubleshooting Connector C367P (pin) Connector C93P (pin) Connector C93S (socket) Connector C367S (socket) Connector C100...
  • Page 153 Troubleshooting HMI displays “BMS No contact.” Refer to CAN investigation subtree Investigate CAN A and CAN C network Complete Were you able to find a Take the actions Is the error code still problem in the CAN A or C prescribed in the subtree.
  • Page 154 Troubleshooting Continued from previous page Does the HMI also display Refer to error F0064 troubleshooting F0064? tree. Does the HMI also display Refer to error F0069 troubleshooting F0069? tree. Does the HMI also display Refer to error F0071 troubleshooting F0071? tree.
  • Page 155 Troubleshooting Continued from previous page Does the HMI Refer to error F0085 troubleshooting also display tree. F0085? WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect fuse F19 from 12V fuse box C14.
  • Page 156 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: MPDM C11 C93P...
  • Page 157 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: C44 S-Box C367P Connector pin Connector pin Pin 10 Pin 7 Pin 11 Pin 7 C40P C367S Connector pin Connector pin Pin 6 Pin 7 C40S C100 Connector pin...
  • Page 158 Is there any evidence of a Defective relay. defect between the pins of Replace relay. the relay? Defective supervisory controller. Replace supervisory controller. Is the error still occurring on further Contact Dana for further key ON or charge investigation. cycles? Complete...
  • Page 159 Troubleshooting Disconnect blown fuse F19 from 12V fuse box C14. Replace fuse F19 from 12V fuse box C14. Restart the vehicle. Did fuse F19 blow again during Complete test drive? WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 160 Is there any evidence Defective harness. of a short circuit within Replace harness. the harness? Replace fuse F19 from 12V fuse box C14. Restart the vehicle. Did fuse F19 blow again Complete during test drive? Contact Dana for further investigation.

  • Page 161: Charging System

    (EVSE) used to Component descriptions change the high voltage system. Vehicles with Dana BEV system must use level 2 or level 3 chargers for proper changing of the HV batteries. The onboard charger (OBC) receives AC or DC input...

  • Page 162: F0003

    Has F0003 appeared in the Charge the vehicle using a fault log in the 3 previous or different EVSE. next 3 charge sessions? Does F003 continue to Complete appear on the HMI or in the fault log? Contact Dana for further investigation.

  • Page 163: F0004

    The vehicle is then enabled to start. If the HV expected to appear. If error F0004 appears alone, distribution system fails to reach the required the technician should contact Dana for further threshold within 5 seconds, the VCU will flag investigation.

  • Page 164: F0005, F0006, F0007 Charge End Reason 1

    Troubleshooting F0005, F0006, F0007 (Charge end reason 1) Error Description Possible Causes Possible Solutions VCU has terminated the charging 1) ESS fault. 1) Troubleshoot specific error. process in response to a request from the BMS. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 165 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 166: Charge End Reason 2

    Troubleshooting F0005, F0006, F0007 (Charge end reason 2) Error Description Possible Causes Possible Solutions VCU has detected a loss of 1) No contact with BMS. 1) Troubleshoot specific error. communication with the BMS during charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 167 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 168: Charge End Reason 3

    Troubleshooting F0005, F0006, F0007 (Charge end reason 3) Error Description Possible Causes Possible Solutions VCU has reported that BMS ended 1) Charging completed 1) No action needed; this is the charging normally. successfully (no error). intended vehicle function. 2) ESS fault. 2) Troubleshoot specific error.
  • Page 169 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the vehicle able to charge completely to Reconnect a compatible EVSE to Complete 100% without raising the start charge. same fault? Contact Dana for further investigation.

  • Page 170: Charge End Reason 4

    Troubleshooting F0005, F0006, F0007 (Charge end reason 4) Error Description Possible Causes Possible Solutions VCU has received a charging error 1) ESS fault. 1) Troubleshoot specific error. message from the BMS. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 171 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 172: Charge End Reason 5

    Troubleshooting F0005, F0006, F0007 (Charge end reason 5) Error Description Possible Causes Possible Solutions VCU has detected that the high 1) Various faults. 1) Troubleshoot specific error. voltage system is offline during charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 173 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 174: Charge End Reason 6

    EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to 100% Complete without raising the same fault? Contact Dana for further investigation.

  • Page 175: Charge End Reason 7

    Troubleshooting F0005, F0006, F0007 (Charge end reason 7) Error Description Possible Causes Possible Solutions BMS has reported a critical 1) ESS fault. 1) Troubleshoot specific error. overvoltage or undervoltage in one or more cells of the ESS. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 176 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 177: Charge End Reason 8

    Troubleshooting F0005, F0006, F0007 (Charge end reason 8) Error Description Possible Causes Possible Solutions BMS reports a critical temperature 1) ESS fault. 1) Troubleshoot specific error. event in the ESS. 2) Incompatible or defective 2) Restart charge with compatible EVSE. EVSE.
  • Page 178 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 179: Charge End Reason 9

    Troubleshooting F0005, F0006, F0007 (Charge end reason 9) Error Description Possible Causes Possible Solutions VCU has reported that the BMS 1) ESS fault. 1) Troubleshoot specific error. has requested a shutdown of the high voltage system. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 180 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 181: Charge End Reason 10

    Troubleshooting F0005, F0006, F0007 (Charge end reason 10) Error Description Possible Causes Possible Solutions VCU has reported that the 1) ESS fault. 1) Troubleshoot specific error. Supervisory controller has requested a shutdown of the high 2) Incompatible or defective 2) Restart charge with compatible voltage system.
  • Page 182 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 183: Charge End Reason 11

    Troubleshooting F0005, F0006, F0007 (Charge end reason 11) Error Description Possible Causes Possible Solutions VCU has detected a high voltage 1) HVIL fault. 1) Troubleshoot specific error. interlock loop (HVIL) error during charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 184 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 185: Charge End Reason 12

    Troubleshooting F0005, F0006, F0007 (Charge end reason 12) Error Description Possible Causes Possible Solutions Charge controller has detected 1) EVSE lost power during 1) No action needed; this is the that the EVSE went offline during charging. intended vehicle function. charging.
  • Page 186 Is the vehicle able to charge completely to Complete 100% without raising the same fault? Investigate the shop power for operation interruptions during charge. Could you find any defect with shop Complete power supply? Contact Dana for further investigation.

  • Page 187: Charge End Reason 13

    Troubleshooting F0005, F0006, F0007 (Charge end reason 13) Error Description Possible Causes Possible Solutions VCU has detected that the cut loop 1) Cut loop fault. 1) Troubleshoot specific error. is broken. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 188 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 189: Charge End Reason 14

    Troubleshooting F0005, F0006, F0007 (Charge end reason 14) Error Description Possible Causes Possible Solutions VCU has reported that the voltage 1) Power management fault. 1) Troubleshoot specific error. on the 12V network is too low. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 190 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 191: Charge End Reason 15

    Troubleshooting F0005, F0006, F0007 (Charge end reason 15) Error Description Possible Causes Possible Solutions Charge controller has detected 1) EVSE disconnected during 1) Reconnect EVSE if further that the EVSE was disconnected charging. charging is needed. from the vehicle during charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 192 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 15 Fault code F0006 and Charge end reason 15 Fault code F0007 and Charge end reason 15 Has the message been raised after the EVSE has been Complete normally unplugged from the vehicle? Unplug EVSE.
  • Page 193 Service Chart” in the Service Manual Pin F1 Pin 1 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence Defective harness. of a continuity loss in Replace harness. the harness? Contact Dana for further investigation.

  • Page 194: Charge End Reason 16

    Troubleshooting F0005, F0006, F0007 (Charge end reason 16) Error Description Possible Causes Possible Solutions BMS has reported that charging is 1) Charging completed 1) No action needed; this is the completed. successfully (no error). intended vehicle function. 2) ESS fault. 2) Troubleshoot specific error.
  • Page 195 High Voltage battery? Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the vehicle able to charge completely to Reconnect a compatible EVSE to Complete 100% without raising the start charge. same fault? Contact Dana for further investigation.

  • Page 196: Charge End Reason 17

    Troubleshooting F0005, F0006, F0007 (Charge end reason 17) Error Description Possible Causes Possible Solutions VCU has detected a high voltage 1) OBC fault. 1) Troubleshoot specific error. interlock loop (HVIL) error in the OBC. 2) No contact with BMS. 2) Troubleshoot specific error. 3) Incompatible or defective 3) Restart charge with compatible EVSE.
  • Page 197 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 17 Fault code F0006 and Charge end reason 17 Fault code F0007 and Charge end reason 17 Unplug charger and put the vehicle in accessory mode. Access the fault log on the HMI. Has error “BMS No contact”...
  • Page 198 Continued from previous page Is the vehicle able to charge completely to Complete 100% without raising the same fault? Has error F0061/F0062/F0088 Refer to the corresponding error 0x3302 been raised previously troubleshooting tree. during or before this charge? Contact Dana for further investigation.

  • Page 199: Charge End Reason 18

    Troubleshooting F0005, F0006, F0007 (Charge end reason 18) Error Description Possible Causes Possible Solutions VCU has detected an error in the 1) OBC fault. 1) Troubleshoot specific error. OBC. 2) No contact with BMS. 2) Troubleshoot specific error. 3) Incompatible or defective 3) Restart charge with compatible EVSE.
  • Page 200 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 18 Fault code F0006 and Charge end reason 18 Fault code F0007 and Charge end reason 18 Unplug charger and put the vehicle in accessory mode. Access the fault log on the HMI. Has error “BMS No contact”...
  • Page 201 Troubleshooting Continued from previous page Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 202: Charge End Reason 19

    Troubleshooting F0005, F0006, F0007 (Charge end reason 19) Error Description Possible Causes Possible Solutions VCU has detected a timeout in 1) OBC fault. 1) Troubleshoot specific error. OBC communication. 2) No contact with OBC. 2) Troubleshoot specific error. The error is expected to be accompanied by the Note: When requested to connect the OBC error (F0088) that triggered the fault.
  • Page 203 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 19 Fault code F0006 and Charge end reason 19 Fault code F0007 and Charge end reason 19 Unplug charger and put the vehicle in accessory mode. Access the fault log on the HMI. Has error “BMS No contact”...
  • Page 204 Troubleshooting Continued from previous page Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 205: Charge End Reason 20

    Troubleshooting F0005, F0006, F0007 (Charge end reason 20) Error Description Possible Causes Possible Solutions VCU has detected a temperature 1) OBC fault. 1) Troubleshoot specific error. error in the OBC. 2) Communication error with 2) Troubleshoot specific error. OBC. The error is expected to be accompanied by the Note: When requested to connect the OBC error (F0088) that triggered the fault.
  • Page 206 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 20 Fault code F0006 and Charge end reason 20 Fault code F0007 and Charge end reason 20 Unplug charger and put the vehicle in accessory mode. Access the fault log on the HMI. Has error “BMS No contact”...
  • Page 207 Troubleshooting Continued from previous page Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 208: Charge End Reason 21

    Troubleshooting F0005, F0006, F0007 (Charge end reason 21) Error Description Possible Causes Possible Solutions VCU timed out while attempting to 1) ESS fault. 1) Troubleshoot specific error. resolve cell voltage imbalance in the ESS. 2) EVSE error. 2) Restart charge session. This error indicates that the charge controller has Note: When requested to connect the detected a cell voltage imbalance in the ESS during...
  • Page 209 Troubleshooting HMI displays or logs Fault code F0005 and Charge end reason 21 Fault code F0006 and Charge end reason 21 Fault code F0007 and Charge end reason 21 Check the High Voltage batteries SOC on the HMI. Drive the truck for a few minutes Has the High Voltage battery in order to discharge the High SOC reached 100%?
  • Page 210 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 211: Charge End Reason 22

    Troubleshooting F0005, F0006, F0007 (Charge end reason 22) Error Description Possible Causes Possible Solutions VCU successfully resolved cell 1) Cell voltage imbalance 1) No action needed; this is the voltage imbalance in the ESS. resolved (no error). intended vehicle function. Note: When requested to connect the This message is not displayed to the driver but may still appear in the HMI fault log.
  • Page 212 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 213: Charge End Reason 23

    Troubleshooting F0005, F0006, F0007 (Charge end reason 23) Error Description Possible Causes Possible Solutions Battery pack being discharged 1) Excessive use of accessories 1) Shut off accessories while during charge. while charging. charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 214 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 215: Charge End Reason 24

    Troubleshooting F0005, F0006, F0007 (Charge end reason 24) Error Description Possible Causes Possible Solutions VCU has terminated the charging 1) ESS fault. 1) Troubleshoot specific error. process and opened the charging relay in response to a request from 2) EVSE error. 2) Restart charge session the BMS.
  • Page 216 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 217: Charge End Reason 25

    Troubleshooting F0005, F0006, F0007 (Charge end reason 25) Error Description Possible Causes Possible Solutions Vehicle is prohibited from starting 1) ESS fault. 1) Troubleshoot specific error. and has been requested to shut down due to an ESS fault. 2) EVSE error. 2) Restart charge session.
  • Page 218 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 219: Charge End Reason 26

    Troubleshooting F0005, F0006, F0007 (Charge end reason 26) Error Description Possible Causes Possible Solutions VCU has reported that the BMS 1) ESS fault. 1) Troubleshoot specific error. has requested to abort charging. 2) Incompatible or defective 2) Restart charge with compatible EVSE.
  • Page 220 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 221: Charge End Reason 27

    Troubleshooting F0005, F0006, F0007 (Charge end reason 27) Error Description Possible Causes Possible Solutions VCU has detected that one or 1) ESS fault. 1) Troubleshoot specific error. more high voltage battery cells have exceeded 3.8 V. 2) EVSE error. 2) Restart charge session. This error is expected to be accompanied by one or If none of these errors has been raised, it may be more of errors F0026, F0047, F0153, or F0154.
  • Page 222 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 223: Charge End Reason 28

    It may be possible to resolve the error by restarting the charge using a compatible EVSE. If not, please vehicle to an EVSE, either a level 2 or level contact Dana for further troubleshooting. 3 EVSE can be used. HMI displays or logs...

  • Page 224: Charge End Reason 29

    Troubleshooting F0005, F0006, F0007 (Charge end reason 29) Error Description Possible Causes Possible Solutions Charge controller status message 1) Charger operating normally 1) No action needed; this is the indicating a specific state of the (no error). intended vehicle function. charge inlet.
  • Page 225 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the truck able to Reconnect a compatible EVSE to charge completely to Complete start charge. 100% without raising the same fault? Contact Dana for further investigation.

  • Page 226: Charge End Reason 30

    Troubleshooting F0005, F0006, F0007 (Charge end reason 30) Error Description Possible Causes Possible Solutions Charge controller status message 1) Charger operating normally 1) No action needed; this is the indicating a specific state of the (no error). intended vehicle function. charge inlet.
  • Page 227 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the truck able to Reconnect a compatible EVSE to charge completely to Complete start charge. 100% without raising the same fault? Contact Dana for further investigation.

  • Page 228: Charge End Reason 31

    Troubleshooting F0005, F0006, F0007 (Charge end reason 31) Error Description Possible Causes Possible Solutions Charge controller status message 1) Charger operating normally 1) No action needed; this is the indicating a specific state of the (no error). intended vehicle function. charge inlet.
  • Page 229 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the vehicle able to Reconnect a compatible EVSE to charge completely to Complete start charge. 100% without raising the same fault? Contact Dana for further investigation.

  • Page 230: Charge End Reason 32

    Troubleshooting F0005, F0006, F0007 (Charge end reason 32) Error Description Possible Causes Possible Solutions Charge controller status message 1) Charger operating normally 1) No action needed; this is the indicating a specific state of the (no error). intended vehicle function. charge inlet.
  • Page 231 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Is the vehicle able to Reconnect a compatible EVSE to charge completely to Complete start charge. 100% without raising the same fault? Contact Dana for further investigation.

  • Page 232: Charge End Reason 33

    Troubleshooting F0005, F0006, F0007 (Charge end reason 33) Error Description Possible Causes Possible Solutions VCU has reported a timeout of the 1) No contact with charge 1) Troubleshoot specific error. charge controller during charging. controller. Note: When requested to connect the vehicle to an EVSE, either a level 2 or level 3 EVSE can be used.
  • Page 233 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 234: Charge End Reason 34

    Troubleshooting F0005, F0006, F0007 (Charge end reason 34) Error Description Possible Causes Possible Solutions VCU has reported a loss of contact 1) OBC fault or no contact with 1) Troubleshoot specific error. with the OBC. OBC. Note: When requested to connect the vehicle to an EVSE, either a level 2 or level 3 EVSE can be used.
  • Page 235 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 236: Charge End Reason 35

    Troubleshooting F0005, F0006, F0007 (Charge end reason 35) Error Description Possible Causes Possible Solutions VCU has reached a state of 1) Charging completed (no error). 1) No action needed; this is the charge ending (after the VCU intended vehicle function. reach the end of charge wait for 5 2) EVSE error.
  • Page 237 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 238: Charge End Reason 36

    Troubleshooting F0005, F0006, F0007 (Charge end reason 36) Error Description Possible Causes Possible Solutions VCU has reported that the BMS 1) ESS fault. 1) Troubleshoot specific error. has requested a shutdown of the high voltage system. 2) EVSE error. 2) Restart charge session. The error is expected to be accompanied by one or Note: When requested to connect the more of F0026 and F0027.
  • Page 239 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact DANA for further investigation.
  • Page 240 Troubleshooting F0088 - Charging system fault This error indicates that the OBC has reported a fault condition. In many cases, the technician will also be referred to the TM4 OBC troubleshooting guide for further To troubleshoot error F0088, locate the OBC fault troubleshooting.
  • Page 241 Troubleshooting Fault Tree Fault Tree Fault Tree Fault Tree Fault Tree Code Ref. Code Ref. Code Ref. Code Ref. Code Ref. 0x1554 0x330A 0x350E 0x4113 0x5500 0x1575 0x330B 0x350F 0x4114 0x5501 0x1576 0x3400 0x3510 0x4115 0x5502 0x1577 0x3401 0x3600 0x4116 0x5503 0x1578 0x3402...
  • Page 242 Troubleshooting F0088 Troubleshooting Tree TT1 Error Description Possible Causes Possible Solutions OBC has detected an internal fault 1) OBC software update needed. 1) Update OBC software. condition. Note: This troubleshooting tree covers the 0x3509, 0x350A, 0x350B, 0x350C, 0x350E, following OBC fault codes: 0x0001, 0x0002, 0x350F, 0x3510, 0x3600, 0x3601, 0x3602, 0x0003, 0x0005, 0x0006, 0x0007, 0x0008, 0x3700, 0x3726, 0x4002, 0x4003, 0x4004,...
  • Page 243 Troubleshooting F0088 Troubleshooting Tree TT2 Error Description Possible Causes Possible Solutions OBC has detected a problem with 1) OBC software update needed. 1) Update OBC software. the EVSE supply or the EVSE connection to the charge inlet. 2) Charge controller fault. 2) Troubleshoot specific error.
  • Page 244 Troubleshooting HVIL 1 HVIL 2 Connector C727 Connector C706 Connector C731 Connector C726...
  • Page 245 Troubleshooting HMI displays or logs Fault code F0088 and OBC fault reason 0x3408/0x3409/ 0x340A/0x340E/0x340F, 0x3725, 0x3727, 0x3728, 0x3729 Update the OBC software version following the STT01 tree provided in the TM4 troubleshooting guide. Is the error still occurring on further Complete key ON or charge cycles?
  • Page 246 Troubleshooting Continued from previous page Disconnect connector C22, C731 and C727 from OBC. WARNING: Electrical hazard. Disconnect connector C100 from ground. Follow Safety Warnings and High Disconnect connector C706 from Voltage Shutdown Procedures HV junction box. defined in the Service Manual Disconnect connector C726 from and Diagnostic Guide.
  • Page 247 Troubleshooting Continued from previous page Is there any evidence of Defective harness. a continuity loss? Replace harness. Do any of the bolted connections appear Defective connection point. scorched, corroded, or Repair or replace appropriately. dirty? Refer to CAN investigation subtree. Investigate CAN B network.
  • Page 248 Troubleshooting F0088 Troubleshooting Tree TT3 Error Description Possible Causes Possible Solutions OBC has detected a problem with 1) OBC software update needed. 1) Update OBC software. the ESS voltage. 2) ESS fault. 2) Troubleshoot specific error. 3) Blown HV fuse F2. 3) Replace HV fuse F2.
  • Page 249 Troubleshooting Connector C716 (black) Connector C719 (orange) Connector C717 (green) Connector C731 Connector C718 (yellow)
  • Page 250 Troubleshooting HMI displays or logs Fault code F0088 and OBC fault reason 0x3505/0x3506/ 0x5401/0x5402/0x5406/0x5407/ 0x5506/0x5507/0x560 Update the OBC software version following the STT01 tree provided in the TM4 troubleshooting guide. Is the error still occurring on further Does the HMI also Refer to Error F0026 key ON or charge display F0026?
  • Page 251 Troubleshooting Continued from previous page Is there any problem with Defective connector. the connector integrity? Replace harness. With a multimeter, check for continuity between the following points: OBC C731P HV JB C706P Connector Connector Pin 1 Pin 1 Pin 2 Pin 2 S-Box C718P HV JB C702P...
  • Page 252 Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Replace fuse and inform Is High Voltage fuse F2 DANA before taking further blown or intermittent? actions. Defective OBC. Replace OBC. Is the error still occurring on...
  • Page 253 Troubleshooting F0088 Troubleshooting Tree TT4 Error Description Possible Causes Possible Solutions OBC over temperature. 1) OBC software update needed. 1) Update OBC software. 2) Powertrain Coolant Pump 2) Troubleshoot specific error. fault. 3) Resolve cooling system 3) Cooling system problem. problem.
  • Page 254 Troubleshooting HMI displays or logs Fault code F0088 and OBC fault reason 0x3750/0x5301 Update the OBC software version following the STT01 tree provided in the TM4 troubleshooting guide. Is the error still occurring on further key ON or Complete charge cycles? Does the HMI also Refer to the corresponding error display F0059 or...
  • Page 255 Troubleshooting F0088 Troubleshooting Tree TT5 Error Description Possible Causes Possible Solutions OBC has detected a CAN 1) OBC software update needed. 1) Update OBC software. communication problem. 2) CAN communication problem. 2) Resolve CAN communication problem. 3) OBC internal error. 3) Replace OBC.
  • Page 256 Refer to CAN investigation subtree Investigate CAN B network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN B actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 257 Troubleshooting F0088 Troubleshooting Tree TT6 Error Description Possible Causes Possible Solutions OBC has detected an internal 1) No error. 1) No action needed. problem. Note: This troubleshooting tree covers the These errors indicate that the OBC has raised an following OBC fault codes: 0x0000, 0x0004, internal status message which does not require any 0x000C, 0x1300, 0x1400, 0x3300, 0x3304, troubleshooting action.
  • Page 258 Troubleshooting F0088 (OBC HVIL Error) Error Description Possible Causes Possible Solutions OBC has reported a discontinuity 1) Analog HVIL fault. 1) Troubleshoot specific error. in the high voltage interlock loop (HVIL). 2) Loss of continuity due to 2) Replace HV harness. defective HV connector or harness.
  • Page 259 Troubleshooting HMI displays or logs Fault code F0088 and OBC HVIL error Does the HMI also display Refer to the corresponding error F0061, F0062 or F0063? troubleshooting tree. Disconnect connector C731 and C727 from OBC. WARNING: Electrical hazard. Follow Safety Warnings and High Refer to connector investigation Voltage Shutdown Procedures subtree.
  • Page 260 Troubleshooting F0131 - Auxiliary current exceeds charger output. Shut off accessories and try again. Error Description Possible Causes Possible Solutions VCU has detected that the high 1) Excessive use of accessories 1) Shut off accessories while voltage batteries are being while charging.
  • Page 261 EVSE if applicable. Wait for vehicle shutdown and wait 2 minutes after shutdown. Reconnect a compatible EVSE to start charge. Is the vehicle able to charge completely to Complete 100% without raising the same fault? Contact Dana for further investigation.

  • Page 262: Charge Controller No Contact

    Troubleshooting Charge controller no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) MPDM fault. 1) Troubleshoot specific error. message from the charge controller within a specified time 2) Loss of continuity due to 2) Replace LV connector or interval.
  • Page 263 Troubleshooting Connector C53 Connector C100...
  • Page 264 Troubleshooting HMI displays “Charge Controller No Contact.” Does the HMI also display “F0072 - Refer to F0072 troubleshooting Check Powertrain tree. Fuse #9”? Disconnect connectors C52 and C53 from CCU. Disconnect connectors C50 and C40. Refer to the connector Disconnect connector C12 from MPDM. investigation subtree.
  • Page 265 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: CCU C53 C50P Connector Connector Pin L1 Pin B CCU C54 C50P Connector Connector Pin G1 Pin B C40S C100 Connector Connector Pin 25 Pin 6 - Continuity : Resistance is less than or equal to 2ohms.
  • Page 266 Troubleshooting OBC no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) MPDM, DCDC, or LV 1) Troubleshoot specific error. message from the OBC within a distribution fault. specified time interval. 2) Replace LV connector or 2) Loss of continuity due to harness per Service Manual.
  • Page 267 Troubleshooting HMI displays “OBC No contact.” Refer to CAN investigation subtree. Investigate CAN B network. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN B actions prescribed in the displayed? network? subtree.
  • Page 268 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter measure the voltage between the following points: OBC C22 OBC C22...
  • Page 269 Ground C100 Connector Connector Pin 22 Pin 1 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. a continuity loss or a Replace harness. degraded connection? Contact Dana for further investigation.

  • Page 270: Propulsion System

    Troubleshooting Propulsion System The propulsion system converts electrical energy Traction Inverter from the ESS into mechanical energy to propel the The traction inverter is the inverter and control unit truck. It consists of an electric motor and a Traction which supplies and controls the motor. The control inverter.
  • Page 271 Troubleshooting F0097, F0098 (Fault Reason 1) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions or 1) No action needed. regenerative braking (F0097) or SOC near 100%. traction (F0098) due to overcurrent 2) Troubleshoot specific error. in the high voltage batteries.
  • Page 272 Refer to the CAN investigation subtree. Investigate CAN B and A network. Were you able to find a defect in the CAN B or A Repair as per the subtree network causing this error instructions. to be raised? Contact Dana for further investigation.
  • Page 273 Troubleshooting F0097, F0098 (Fault Reason 2) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) ESS fault. 1) Troubleshoot specific error. regenerative braking (F0097) or traction (F0098) due to a traction 2) Traction inverter software or 2) Update traction inverter inverter internal error.
  • Page 274 Troubleshooting Connector C717 (green) Connector C719 (orange) Connector C718 (yellow)
  • Page 275 Troubleshooting HMI displays or logs Fault code F0097 and Fault reason 2 Fault code F0098 and Fault reason 2 Does the HMI also Refer to the F0026 display F0026? troubleshooting tree. Is any other system on the high voltage bus raising an error? Flash the traction inverter to the latest software and calibration following the...
  • Page 276 HV JB C701P S-Box C716P Connector pin Connector pin Pin 1 Pin 1 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. a continuity loss? Replace harness. Contact Dana for further investigation.
  • Page 277 Troubleshooting F0097, F0098 (Fault Reason 3) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) No action needed. regenerative braking (F0097) or traction (F0098) due to overspeed. 2) Traction inverter software or 2) Update traction inverter calibration error.
  • Page 278 Troubleshooting HMI displays or logs Fault code F0097 and Fault reason 3 Fault code F0098 and Fault reason 3 Was this error raised in a steep slope or at a speed Complete higher than 70mph? Flash the traction inverter to the latest software and calibration following the instructions in the TM4 installation manual.
  • Page 279 Troubleshooting Continued from previous page Is there any evidence of a short or a conductivity Defective harness. problem on the speed sensor Replace harness. cables? Refer to connector investigation subtree. Inspect the traction inverter connectors. Were there any defects on the Defective traction inverter.
  • Page 280 Troubleshooting F0097, F0098 (Fault Reason 4) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) Park vehicle outdoors out of regenerative braking (F0097) or the sun and allow it to cool traction (F0098) due to down for 2 hours.
  • Page 281 Troubleshooting HMI displays or logs Fault code F0097 and Fault reason 4 Fault code F0098 and Fault reason 4 Did the fault clear during normal Complete operation? Did the error occur under extreme conditions: Max speed, Let the truck cool down for 2 hours Max torque, steep uphill/ parked outside not under the sun downhill, extremely hot...
  • Page 282 Troubleshooting Continued from previous page Is the VCU displaying Refer to the specific error ‘’Powertrain Coolant troubleshooting tree. Pump No Contact’’? Is the VCU displaying ‘’Radiator Fan 01 No Refer to the specific error Contact’’ or ‘’Radiator Fan troubleshooting tree. 02 No Contact’’? Refer to the cooling system investigation subtree.
  • Page 283 Troubleshooting F0097, F0098 (Fault Reason 5) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Traction inverter software or 1) Update traction inverter regenerative braking (F0097) or calibration error. software and calibration. traction (F0098) due to a traction inverter internal error.
  • Page 284 Troubleshooting F0097, F0098 (Fault Reason 6) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) No action needed. regenerative braking (F0097) or traction (F0098) due to due to the 2) Traction inverter software or 2) Update traction inverter propulsion system exceeding its calibration error.
  • Page 285 Complete speed? Flash the traction inverter to the latest software and calibration following the instructions in the TM4 installation manual. Is the problem persisting on further Complete drive cycles in similar conditions? Contact Dana for further investigation.
  • Page 286 Troubleshooting F0097, F0098 (Fault Reason 7) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) ESS fault. 1) Troubleshoot specific error. regenerative braking (F0097) or traction (F0098) because the 2) Loss of continuity due to 2) Replace HV harness. voltage of the HV supply is out of defective HV connector or range.
  • Page 287 Troubleshooting Connector C716 (black) Connector C718 (yellow) Connector C717 (green) Connector C719 (orange)
  • Page 288 TM4 guide? Flash the traction inverter to the latest Is the problem software and calibration following the Complete persisting on further instructions in the TM4 installation drive cycles? manual. Contact Dana for further investigation.
  • Page 289 HV JB C701P S-Box C717P Connector pin Connector pin Pin 1 Pin 1 HV JB C701P S-Box C716P Connector pin Connector pin Pin 1 Pin 1 - Continuity : Resistance is less than or equal to 2ohms. Contact Dana for further investigation.
  • Page 290 Troubleshooting F0097, F0098 (Fault Reason 8) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) Park vehicle outdoors out of regenerative braking (F0097) or the sun and allow it to cool traction (F0098) due to down for 2 hours.
  • Page 291 Troubleshooting HMI displays or logs Fault code F0097 and Fault reason 8 Fault code F0098 and Fault reason 8 Did the fault clear during normal Complete operation? Did the error occur under extreme conditions: Max speed, Let the truck cool down for 2 hours Max torque, steep uphill/ parked outside not under the sun downhill, extremely hot...
  • Page 292 Troubleshooting Continued from previous page Is the VCU displaying Refer to the specific error ‘’Powertrain Coolant troubleshooting tree. Pump No Contact’’? Is the VCU displaying ‘’Radiator Fan 01 No Refer to the specific error Contact’’ or ‘’Radiator Fan troubleshooting tree. 02 No Contact’’? Refer to the cooling system investigation subtree.
  • Page 293 Troubleshooting F0097, F0098 (Fault Reason 9) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) Park vehicle outdoors out of regenerative braking (F0097) or the sun and allow it to cool traction (F0098) due to down for 2 hours.
  • Page 294 Troubleshooting HMI displays or logs Fault code F0097 and Fault reason 9 Fault code F0098 and Fault reason 9 Did the fault clear during normal Complete operation? Did the error occur under extreme conditions: Max speed, Let the truck cool down for 2 hours Max torque, steep uphill/ parked outside not under the sun downhill, extremely hot...
  • Page 295 02 No Contact’’? Refer to the cooling system investigation subtree. Were you able to find a defect in the cooling system Repair as per the subtree causing this error to be instructions. raised? Contact Dana for further investigation.
  • Page 296 Troubleshooting F0097, F0098 (Fault Reason 10) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Motor internal failure. 1) Replace motor. regenerative braking (F0097) or traction (F0098) due to an internal failure of the motor. Propulsion System faults may also be investigated and resolved using the ODIN tool and the TM4 SUMO Powertrain Troubleshooting Guide.
  • Page 297 Troubleshooting F0097, F0098 (Fault Reason 11) Error Description Possible Causes Possible Solutions Traction inverter has limited 1) Adverse driving conditions. 1) Park vehicle outdoors out of regenerative braking (F0097) or the sun and allow it to cool traction (F0098) due to overcurrent down for 2 hours.
  • Page 298 Does the fault occur again during Complete a test drive? Flash the traction inverter to the latest Is the problem software and calibration following the Contact Dana for further persisting on further instructions in the TM4 installation investigation. drive cycles? manual.
  • Page 299 Troubleshooting F0099 - Propulsion system fault Error Description Possible Causes Possible Solutions Traction inverter has reported an 1) Blown MPDM fuse F5. 1) Replace MPDM fuse F5. internal failure or traction inverter has requested emergency stop. 2) Blown 12V fuse F19. 2) Replace 12V fuse F19.
  • Page 300 Troubleshooting Connector C676 Connector C40 Connector C93P (pin) Connector C50 Connector C93S (socket) Connector C53 Connector C91...
  • Page 301 Troubleshooting HMI displays or logs Fault code F0099 Turn ignition OFF. Inspect fuse F5 and F4 on MPDM and fuse F19 on 12V fuse box C14. Is fuse F5 on MPDM blown or intermittent? Is fuse F19 on 12V fuse box C14 blown or intermittent? Is fuse F4 on MPDM blown or...
  • Page 302 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: MPDM C11 K004 C4...
  • Page 303 Inspect fuse F3 in the HV junction box. Complete Is HV fuse F3 fully operational or at the correct Contact Dana for further rating as per the PACCAR investigation. installation instructions? Replace HV fuse F3. Inform DANA of that replacement...
  • Page 304 Troubleshooting Complete Disconnect blown fuse F5 from Replace fuse F5 on MPDM. Did fuse F5 blow again MPDM. Restart the vehicle. during test drive? Refer to the connector Disconnect connector C11 from Turn ignition OFF and investigation subtree. MPDM. disconnect F5 from MPDM. Defective connector.
  • Page 305 Is there any evidence Defective harness. of a short circuit? Replace harness. Replace fuse F5 from MPDM. Replace relay K004. Reconnect all previously disconnected connectors. Restart the vehicle. Did fuse F5 blow Contact Dana for further again during test investigation. drive? Complete...
  • Page 306 Troubleshooting Complete Replace fuse F19 on 12V fuse Disconnect blown fuse F19 from Did fuse F19 blow again box C14. 12V fuse box C14. during test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect C53 and C54 from disconnect F19 from 12V fuse investigation subtree.
  • Page 307 Replace harness. Replace fuse F19 on 12V fuse box C14. Replace relay K004 and K005. Reconnect all previously disconnected connectors. Restart the vehicle. Did fuse F19 blow again Contact Dana for further during test drive? investigation. Complete...
  • Page 308 Troubleshooting Complete Disconnect blown fuse F4 from Replace fuse F4 on MPDM. Did fuse F4 blow again MPDM. Restart the vehicle. during test drive? Refer to the connector Disconnect connector C11 Turn ignition OFF and investigation subtree. from MPDM. disconnect F4 from MPDM. Defective connector.
  • Page 309 Is there any evidence Defective harness. of a short circuit? Replace harness. Replace fuse F4 from MPDM. Replace relay K005. Reconnect all previously disconnected connectors. Restart the vehicle. Does fuse F4 blow again Complete during a test drive? Contact Dana for further investigation.
  • Page 310 Troubleshooting F0100 (Fault Reason 1) Error Description Possible Causes Possible Solutions Traction inverter has detected a 1) Causes covered in traction 1) Refer to traction inverter short circuit between the motor inverter troubleshooting guide. troubleshooting guide. phase cables and the vehicle chassis.
  • Page 311 Troubleshooting F0100 (Fault Reason 2) Error Description Possible Causes Possible Solutions Traction inverter has detected an 1) Defective LV connector or 1) Replace LV connector or unplugged connector between the harness between traction harness per Service Manual. traction inverter and motor. inverter and speed sensor.
  • Page 312 Troubleshooting HMI displays or logs Fault code F0100 and Traction inverter fault reason 2 Does the HMI also Contact Dana for further display F0061 or investigation. F0062? WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 313 Troubleshooting Continued from previous page Defective connector. Replace the connector as Reconnect the speed sensor Is there any connector described in the “Wire Harness connector to the motor integrity issue? Connector Identification, speed sensor. Location, and Service Chart” in the Service Manual. Turn ignition ON.
  • Page 314 Troubleshooting Continued from previous page Is the error message still Defective harness. appearing on the HMI? Replace harness. Turn ignition OFF. Place the jumper between pin J and K on connector C3 on the traction inverter. Turn ignition ON Is the error message still Defective traction inverter.
  • Page 315 Troubleshooting F0100 (Fault Reason 3) Error Description Possible Causes Possible Solutions Traction inverter has detected an 1) Connector C3 on the traction 1) Plug in connector C3. unplugged connector on the inverter is unplugged. traction inverter LV side. 2) Replace harness. 2) Loss of continuity due to defective LV connector.
  • Page 316 Troubleshooting HMI displays or logs Fault code F0100 and Traction inverter fault reason 3 WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Disconnect connector C3 from the traction inverter. Refer to the connector investigation subtree.
  • Page 317 Troubleshooting F0100 (Fault Reason 4) Error Description Possible Causes Possible Solutions Traction inverter has detected that 1) Traction inverter cover not 1) Install traction inverter cover the traction inverter cover is not installed properly. properly. installed properly. 2) Causes covered in traction 2) Refer to traction inverter inverter troubleshooting guide.
  • Page 318 Troubleshooting F0102 - Downhill braking reduced! Apply brakes as needed. Error Description Possible Causes Possible Solutions Normal level of regenerative 1) Adverse driving conditions or 1) No action needed. braking is not available while SOC near 100%. cruise control is active. 2) Troubleshoot specific error.
  • Page 319 Does the HMI display Refer to the F0026 troubleshooting F0026? tree. Refer to the TM4 traction inverter Was this error raised with troubleshooting guide. Refer to the cruise control active? ‘’Motor Speed reached Maximum’’ tree. Contact Dana for further investigation.
  • Page 320 F0103 - Regenerative Braking reduced Error Description Possible Causes Possible Solutions Traction inverter software error 1) Traction inverter software 1) Contact Dana. which requires support from Dana. error. HMI displays or logs Fault code F0103 Contact Dana for further investigation.
  • Page 321 Troubleshooting F0104 - Accelerator pedal sensor error Error Description Possible Causes Possible Solutions VCU has detected that the 1) Loss of continuity due to 1) Replace LV connector or accelerator pedal sensor signals defective LV connector or harness per Service Manual. are mismatched or out of range.
  • Page 322 Troubleshooting Circuit73 Connector C651.B...
  • Page 323 Troubleshooting HMI displays or logs Fault code F0104 Turn ignition OFF. Disconnect connector C655 from acceleration pedal. Disconnect connector C651.A and C651.B from VCU. Refer to the connector investigation subtree. Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart”...
  • Page 324 Troubleshooting Traction Inverter no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) Propulsion fault. 1) Troubleshoot specific error. message from the Traction inverter within a specified time interval. 2) CAN communication problem. 2) Resolve CAN communication problem.

  • Page 325: Brake System

    Troubleshooting Brake System The brake system is responsible for stopping the iAPU vehicle. The brakes are operated by compressed air The intelligent Air Processing Unit (iAPU) controls supplied by an onboard compressor. the air brake compressor to maintain the brake system pressure within the operational range.

  • Page 326: Fault Reason 0X02Faff

    Troubleshooting F0000 (Fault Reason 0x02faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x02faff Defective iAPU. Replace iAPU.

  • Page 327: Fault Reason 0X05Faff

    Troubleshooting F0000 (Fault Reason 0x05faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x05faff Defective iAPU. Replace iAPU.

  • Page 328: Fault Reason 0X07Faff

    F0000 (Fault Reason 0x07faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Contact Dana. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x07faff Contact Dana for further investigation.

  • Page 329: Fault Reason 0X08Faff

    F0000 (Fault Reason 0x08faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Contact Dana. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x08faff Contact Dana for further investigation.

  • Page 330: Fault Reason 0X0Afae0, 0X0Afaf0

    Reset the fault using the Bendix service tool as per the Bendix service manual. Confirm reset using Bendix tool before going forward. Is the error message raised again Complete shortly after replacing the cartridge? Contact Dana for further investigation.

  • Page 331: Fault Reason 0X233302

    Troubleshooting F0000 (Fault Reason 0x233302) Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Low oil level in air brake 1) Repair any leaks and refill oil. a low oil level. compressor. 2) Replace air brake compressor. 2) Air brake compressor internal failure.
  • Page 332 Fault code F0000 and Air Brake DTC 0x233302 Check the air brake compressor oil level. Is the air brake Contact Dana for further compressor oil level investigation. low? Check for oil leaks on and Repair the leak according to the...

  • Page 333: Fault Reason 0X233608, 0X233708, 0X233808

    2) iAPU internal failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x233608/0x233708/0x233808 Does the HMI also display Refer to the corresponding any other iAPU or air brake troubleshooting tree. compressor DTC number? Contact Dana for further investigation.

  • Page 334: Fault Reason 0X233B0A

    Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Air brake compressor internal 1) Contact Dana. an internal failure. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x233B0A Contact Dana for further investigation.

  • Page 335: Fault Reason 0X234101

    Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Air brake compressor internal 1) Contact Dana. an internal failure. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x234101 Contact Dana for further investigation.

  • Page 336: Fault Reason 0X234606, 0X234705

    Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Air brake compressor internal 1) Contact Dana. an internal failure. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0x234606/234705 Contact Dana for further investigation.

  • Page 337: Fault Reason 0Xa1F8Ec

    Possible Solutions iAPU has reported that the air 1) Air brake compressor internal 1) Contact Dana. brake compressor electric motor failure. experienced an overload. HMI displays or logs Fault code F0000 and Air Brake DTC 0xa1f8ec Contact Dana for further investigation.

  • Page 338: Fault Reason 0Xa3F8Ec

    Error Description Possible Causes Possible Solutions iAPU has reported an air brake 1) Air brake compressor internal 1) Contact Dana. compressor internal failure. failure. HMI displays or logs Fault code F0000 and Air Brake DTC 0xa3f8ec Contact Dana for further investigation.

  • Page 339: Fault Reason 0Xa4F8F2

    Troubleshooting F0000 (Fault Reason 0xa4f8f2) Error Description Possible Causes Possible Solutions iAPU has reported a low oil level in 1) Low oil level in air brake 1) Repair any leaks and refill oil. the air brake compressor. compressor. 2) Replace air brake compressor. 2) Air brake compressor internal failure.
  • Page 340 Fault code F0000 and Air Brake DTC 0xa4f8f2 Check the air brake compressor oil level. Is the air brake Contact Dana for further compressor oil level investigation. low? Check for oil leaks on and Repair the leaks according to the...

  • Page 341: Fault Reason 0Xa4F8Ff

    Change the air brake compressor oil according to Bendix procedure. Reset the fault using the Bendix service tool as per the Bendix service manual. Confirm reset using Bendix tool before going forward. Does error F0000 occur Complete again? Contact Dana for further investigation.

  • Page 342: Fault Reason 0Xa5F8F0

    Troubleshooting F0000 (Fault Reason 0xa5f8f0) Error Description Possible Causes Possible Solutions iAPU has reported that the air 1) Problem with cooling system. 1) Resolve cooling system brake compressor electric motor problem. and/or circuitry are overheated. 2) Air brake compressor internal failure.
  • Page 343 Troubleshooting HMI displays or logs Fault code F0000 and Air Brake DTC 0xa5f8f0 Turn ignition OFF and wait until compressor temperature is below 85°C. Perform a test drive to check if the error is being raised again. Is the error eventually raised Complete again?

  • Page 344: Fault Reason 0Xa6F8F0

    Troubleshooting F0000 (Fault Reason 0xa6f8f0) Error Description Possible Causes Possible Solutions iAPU has reported that the air 1) Problem with cooling system. 1) Resolve cooling system brake compressor mechanism is problem. overheated. 2) Air brake compressor internal failure. 2) Replace air brake compressor.
  • Page 345 Troubleshooting HMI displays or logs Fault code F0000 and Air Brake DTC 0xa6f8f0 Turn ignition OFF and wait until compressor temperature is below 85°C. Perform a test drive to check if the error is being raised again. Is the error eventually Complete raised again? Refer to the cooling investigation...

  • Page 346: Fault Reason 0Xa7F8Ec

    1) Loss of contact with iAPU or 1) Troubleshoot specific error. communication with the air brake air brake compressor. compressor. 2) Resolve CAN communication 2) CAN communication problem. problem. 3) Air brake compressor internal 3) Contact Dana. failure. 4) Contact Dana. 4) iAPU internal failure.
  • Page 347 Refer to CAN investigation subtree Investigate CAN A network. Complete Were you able to find a Take the actions Is the error code still problem in the CAN A prescribed in the subtree. displayed? network? Contact Dana for further investigation.

  • Page 348: Fault Reason 0Xcef9F0, 0Xd1F9Ef

    Possible Solutions iAPU has reported that one of the 1) Pressure temporarily high. 1) Put vehicle in accessory mode onboard pneumatic circuits has and pump brakes to reduce reached its maximum pressure pressure. 2) iAPU internal failure. level. 2) Contact Dana.
  • Page 349 Put the truck in ready mode after reducing the pressure in the brake circuit. Allow air brake to run and fill the system. Wait at least 1 minute after filling. Does the error code Contact Dana for further appear again? investigation. Complete...

  • Page 350: Fault Reason 0Xd5F9F0, 0Xd6F9E1

    Troubleshooting F0000 (Fault Reason 0xd5f9f0, 0xd6f9e1) Error Description Possible Causes Possible Solutions iAPU has detected possible 1) Air dryer cartridge in need of 1) Drain excess water from condensed water in the pneumatic replacement. system and replace air dryer system. cartridge.
  • Page 351 Troubleshooting HMI displays or logs Fault code F0000 and Air Brake DTC 0xd6f9e1/0xd5f9f0 Inspect all the air brake system for air leaks. Could you find any air leaks on the iAPU or the Repair any air leaks. air brake circuits? Drain water from the wet tank by the iAPU by opening the air tank purge valve at the bottom of the...

  • Page 352: Fault Reason 0Xd9F9E2

    Troubleshooting F0000 (Fault Reason 0xd9f9e2) Error Description Possible Causes Possible Solutions iAPU has reported an improbably 1) iAPU internal error. 1) Follow trouble tree to resolve. high pressure in one of the Possible IAPU replacement. onboard pneumatic circuits.
  • Page 353 Depressurize the air tanks, service brake and suspension circuits. Fill air brake system until air brake compressor cut off pressure. Repeat the two previous steps 2 more times. Cycle ignition. Does the error code Contact Dana for further appear again? investigation. Complete...

  • Page 354: Fault Reason 0Xdaf9E2

    Troubleshooting F0000 (Fault Reason 0xdaf9e2) Error Description Possible Causes Possible Solutions iAPU has reported an improbably 1) iAPU internal error. 1) Follow trouble tree to resolve. high pressure in one of the Possible IAPU replacement. onboard pneumatic circuits.
  • Page 355 Depressurize the air tanks, service brake and suspension circuits. Fill air brake system until air brake compressor cut off pressure. Repeat the two previous steps 2 more times. Cycle ignition. Does the error code Contact Dana for further appear again? investigation. Complete...

  • Page 356: Fault Reason 0Xfef9Ff

    HMI displays or logs Fault code F0000 and Air Brake DTC 0xfef9ff Reset the fault using the Bendix service tool as per the Bendix service manual. Does error F0000 0xfef9ff Complete occur again? Contact Dana for further investigation.

  • Page 357: F0001

    1) Replace air dryer cartridge. replacement. replacement. HMI displays or logs Fault Code F0001 Replace air dryer filter. Reset the fault using the Bendix service tool as per the Bendix service manual. Does error F0001 occur Complete again? Contact Dana for further investigation.

  • Page 358: Fault Reason 0X00Faff

    Troubleshooting F0002 (Fault Reason 0x00faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x00faff Defective iAPU. Replace iAPU.

  • Page 359: Fault Reason 0X01Faff

    Troubleshooting F0002 (Fault Reason 0x01faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x01faff Defective iAPU. Replace iAPU.

  • Page 360: Fault Reason 0X03Faff

    Troubleshooting F0002 (Fault Reason 0x03faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x03faff Defective iAPU. Replace iAPU.

  • Page 361: Fault Reason 0X04F9E2

    Troubleshooting F0002 (Fault Reason 0x04f9e2) Error Description Possible Causes Possible Solutions iAPU CAN Bus off failure occurred 1) No contact with iAPU or air 1) Troubleshoot specific error. brake compressor. 2) Resolve CAN communication 2) CAN communication problem. problem.
  • Page 362 Refer to CAN investigation subtree Investigate CAN A network Complete Were you able to find a Take the actions Is the error code still problem in the CAN A prescribed in the subtree. displayed? network? Contact Dana for further investigation.

  • Page 363: Fault Reason 0X04Faff

    Troubleshooting F0002 (Fault Reason 0x04faff) Error Description Possible Causes Possible Solutions iAPU has detected an internal 1) Air leak from port 41 on iAPU. 1) Correctly plug port 41 on pressure sensor failure. iAPU. 2) iAPU internal failure. 2) Replace iAPU. HMI displays or logs Fault code F0002 and Air Brake DTC 0x04faff...

  • Page 364: Fault Reason 0X06Faff

    Troubleshooting F0002 (Fault Reason 0x06faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x06faff Defective iAPU. Replace iAPU.

  • Page 365: Fault Reason 0X09Faff

    F0002 (Fault Reason 0x09faff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Contact Dana. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x09faff Contact Dana for further investigation.

  • Page 366: Fault Reason 0X232802

    Troubleshooting F0002 (Fault Reason 0x232802) Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) ESS fault. 1) Troubleshoot specific error. a critical undervoltage on its HV supply. 2) Loss of continuity due to 2) Replace HV harness. defective HV connector or harness.
  • Page 367 Troubleshooting HMI displays or logs Fault code F0002 and Air Brake DTC 0x232802 Does the HMI also Refer to the corresponding display F0017 or troubleshooting tree. F0026? WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 368 Service Manual and Diagnostic Guide. Inspect fuse F4 in the HV junction box. Replace HV fuse and advise DANA that the fuse was blown before restarting the truck. Is fuse F4 blown or intermittent? WARNING: Electrical hazard.

  • Page 369: Fault Reason 0X232B01

    Air brake compressor has reported 1) HV distribution problem. 1) Contact Dana. a problem with the HV distribution system which requires support from Dana. HMI displays or logs Fault code F0002 and Air Brake DTC 0x232B01 Contact Dana for further investigation.

  • Page 370: Fault Reason 0X232C01

    Troubleshooting F0002 (Fault Reason 0x232C01) Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) ESS fault. 1) ESS fault. an overload condition. 2) Air brake compressor internal 2) Air brake compressor internal failure. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x232C01 Does the HMI also display...

  • Page 371: Fault Reason 0X232D09, 0X232E09

    Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Air brake compressor internal 1) Contact Dana. an internal failure. failure. HMI displays or logs Fault code F0002 and Air Brake DTC 0x232D09/0x232E09 Contact Dana for further investigation.

  • Page 372: Fault Reason 0X232F01, 0X233001

    Troubleshooting F0002 (Fault Reason 0x232F01, 0x233001) Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Problem with cooling system. 1) Resolve cooling system that it is overheated. problem. 2) Air brake compressor internal failure. 2) Replace air brake compressor.
  • Page 373 Troubleshooting HMI displays or logs Fault code F0002 and Air Brake DTC 0x232F01/0x233001 Turn ignition OFF and wait until compressor temperature is below 85°C. Turn ignition ON. Is the error eventually Complete raised again? Refer to the cooling investigation subtree. Repair the defect as per the Was a defect found in instruction in the...

  • Page 374: Fault Reason 0X234209

    1) Contact Dana an overcurrent condition on the compressor problem analog high voltage interlock loop (HVIL). Feature is not enabled. Contact Dana if this fault reason occurs. HMI displays or logs Fault code F0002 and Air Brake DTC 0x234209 Contact Dana for...

  • Page 375: Fault Reason 0X234309, 0X234409, 0X234509

    (HVIL). 2) Analog HVIL fault. 2) Troubleshoot specific error. 3) Air brake compressor internal 3) Contact Dana. failure. The purpose of the HVIL is to provide a warning if any HV connector is unplugged without the HV distribution being safely ended. The air brake compressor monitors continuity between the HVIL pins on its HV connector (C790).
  • Page 376 Fault code F0002 and Air brake DTC 0x234309 Fault code F0002 and Air brake DTC 0x234409 Fault code F0002 and Air brake DTC 0x234509 Does the HMI also display Contact Dana for further F0140? investigation. Does the HMI also display...
  • Page 377 Air brake Compressor C790P Air brake Compressor C790P Connector pin Connector pin Pin 3 Pin 4 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.

  • Page 378: Fault Reason 0X23480A, 0X234907

    Error Description Possible Causes Possible Solutions Air brake compressor has reported 1) Air brake compressor internal 1) Contact Dana. an internal failure. failure. HMI displays or logs Fault code F0002 and Air brake DTC 0x23480A/0x234907 Contact Dana for further investigation.

  • Page 379: Fault Reason 0X3Cf8E3

    Troubleshooting F0002 (Fault Reason 0x3cf8e3) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air brake DTC 0x3cf8e3 Defective iAPU. Replace iAPU.

  • Page 380: Fault Reason 0X3Df8Ff

    Troubleshooting F0002 (Fault Reason 0x3df8ff) Error Description Possible Causes Possible Solutions iAPU has reported an internal 1) iAPU internal failure. 1) Replace iAPU. failure. HMI displays or logs Fault code F0002 and Air brake DTC 0x3df8ff Defective iAPU. Replace iAPU.

  • Page 381: Fault Reason 0X4Ff8E4

    2) Replace 24V fuse F2. 3) Loss of continuity due to 3) Replace LV connector or defective LV connector or harness per Service Manual. harness. 4) Contact Dana. 4) iAPU internal failure. Connector C40 Connector C367P (pin) Connector C203 Connector C367S (socket)
  • Page 382 Troubleshooting HMI displays or logs Fault code F0002 and Air brake DTC 0x4ff8e4 Does the HMI also display Refer to the corresponding F0008 or F0095? troubleshooting tree. Disconnect connector C203 from iAPU. Disconnect connector C101 from ground. Refer to the connector investigation subtree.
  • Page 383 Troubleshooting Continued from previous page Is the voltage Defective iAPU. measurement between Replace iAPU. 16V – 32V? Inspect fuse F2 on 24V fuse box C20. Is fuse F2 on 24V fuse box C20 blown or intermittent ? Turn ignition OFF. Disconnect connector C40 and C367.
  • Page 384 Pin 2 C367S iAPU C203 Connector pin Connector pin Pin 2 Pin 2 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.
  • Page 385 -Inspect all connectors and wires between the two test points of the harness ends. Replace F2 on 24V fuse box C20. Restart the vehicle. Does fuse F2 blow again Complete during a test drive? Contact Dana for further investigation.

  • Page 386: Fault Reason 0X74F7Ec, 0X75F7Ed

    Troubleshooting F0002 (Fault Reason 0x74f7ec, 0x75f7ed) Error Description Possible Causes Possible Solutions iAPU has reported a dataset or 1) iAPU dataset or software error. 1) Update dataset using Bendix software error. service tool. HMI displays or logs Fault code F0002 and Air brake DTC 0x75f7ed / 0x74f7ec Using the Bendix service tool, download the latest dataset into the iAPU.

  • Page 387: Fault Reason 0Xa1F8E2

    Troubleshooting F0002 (Fault Reason 0xa1f8e2) Error Description Possible Causes Possible Solutions iAPU has reported input 1) ESS fault. 1) Troubleshoot specific error. undervoltage or overvoltage at the air brake compressor. 2) Loss of continuity due to 2) Replace HV harness. defective HV connector or harness.
  • Page 388 Troubleshooting HMI displays or logs Fault code F0002 and Air brake DTC 0xa1f8e2 Does the HMI also display Refer to the corresponding error F0017 or F0026? troubleshooting tree. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 389 Contact Dana for further Is fuse F4 blown or investigation. intermittent? Replace HV fuse and advise DANA that the fuse was blown before restarting the truck. WARNING: Electrical hazard. The High Voltage junction box cover and all HV connections must be reinstalled properly after replacing the fuse and before restarting the truck.

  • Page 390: Fault Reason 0Xa2F8Ec

    Possible Causes Possible Solutions iAPU has reported an internal 1) Air brake compressor internal 1) Contact Dana. failure in the air brake compressor. failure. HMI displays or logs Fault code F0002 and Air brake DTC 0xa2f8ec Contact Dana for further investigation.

  • Page 391: Fault Reason 0Xa5F8E0

    Troubleshooting F0002 (Fault Reason 0xa5f8e0) Error Description Possible Causes Possible Solutions iAPU has reported that the air 1) Problem with cooling system. 1) Resolve cooling system brake compressor electric motor problem. and/or circuitry are critically 2) Air brake compressor internal overheated.

  • Page 392: Fault Reason 0Xa6F8E0

    Troubleshooting F0002 (Fault Reason 0xa6f8e0) Error Description Possible Causes Possible Solutions iAPU has reported that the air 1) Problem with cooling system. 1) Resolve cooling system brake compressor mechanism is problem. critically overheated. 2) Air brake compressor internal failure. 2) Replace air brake compressor. HMI displays or logs Fault code F0002 and Air brake DTC 0xa6f8e0...

  • Page 393: Fault Reason 0Xd0F9E4

    Troubleshooting F0002 (Fault Reason 0xd0f9e4) Error Description Possible Causes Possible Solutions iAPU has reported low air pressure 1) Air leak in primary brake 1) Repair leak. in the primary brake circuit. circuit. 2) Replace iAPU. 2) iAPU internal failure. 3) Replace air brake compressor. 3) Air brake compressor internal failure.
  • Page 394 Troubleshooting HMI displays or logs Fault code F0002 and Air brake DTC 0xd0f9e4 Check the air pressure in the air tank of the primary brake circuit. Is the primary circuit Defective iAPU. pressure less than 4.8bar? Replace iAPU. Check that the air brake compressor is running.
  • Page 395 Troubleshooting Continued from previous page Are there any leaks in Inspect the iAPU for air the primary circuit? leaks. Repair any air leaks and Are there any air Defective iAPU. refill the air tanks by leaks? Replace iAPU. turning ignition ON. Is the same error message Defective iAPU.

  • Page 396: Fault Reason 0Xd3F9E4

    Troubleshooting F0002 (Fault Reason 0xd3f9e4) Error Description Possible Causes Possible Solutions iAPU has reported low air pressure 1) Air leak in secondary brake 1) Repair leak. in the secondary brake circuit. circuit. 2) Replace iAPU. 2) iAPU internal failure. 3) Replace air brake compressor. 3) Air brake compressor internal failure.
  • Page 397 Troubleshooting HMI displays or logs Fault code F0002 and Air brake DTC 0xd3f9e4 Check the air pressure in the air tank of the secondary brake circuit. Is the secondary circuit Defective iAPU. pressure less than 4.8bar? Replace iAPU. Check that the air brake compressor is running.
  • Page 398 Troubleshooting Continued from previous page Are there any leaks in Inspect the iAPU for air the secondary circuit? leaks. Repair any air leaks and Are there any air Defective iAPU. refill the air tanks by leaks? Replace iAPU. turning ignition ON. Is the same error message Defective iAPU.

  • Page 399: Fault Reason 0Xd4F9E2

    Troubleshooting F0002 (Fault Reason 0xd4f9e2) Error Description Possible Causes Possible Solutions iAPU has reported an implausible 1) Temporary pressure 1) Reduce air pressure and allow pressure reading in the pneumatic imbalance. to refill. circuits. 2) iAPU internal failure. 2) Replace iAPU. HMI displays or logs Fault code F0002 and Air brake DTC 0xd4f9e2...

  • Page 400: Fault Reason 0Xe2F9E4

    1) Software error 1) Contact Dana. in the parking brake circuit. This feature is not used. If this error is raised the technician should contact Dana. HMI displays or logs Fault code F0002 and Air brake DTC 0xe2f9e4 Contact Dana for further...

  • Page 401: Fault Reason 0Xe3F9E4

    1) Software error 1) Contact Dana. in the auxiliary circuit. This feature is not used. If this error is raised the technician should contact Dana. HMI displays or logs Fault code F0002 and Air brake DTC 0xe3f9e4 Contact Dana for further...

  • Page 402: Fault Reason 0Xe4F9E4

    Troubleshooting F0002 (Fault Reason 0xe4f9e4) Error Description Possible Causes Possible Solutions iAPU has reported low air pressure 1) iAPU internal failure. 1) Replace iAPU. in circuit 5. HMI displays or logs Fault code F0002 and Air brake DTC 0xe4f9e4 Circuit 5 is not configured. This error message indicates and internal problem with the iAPU.
  • Page 403 (HVIL). 2) Analog HVIL fault. 2) Troubleshoot specific error. 3) Air brake compressor internal 3) Contact Dana. failure. The purpose of the HVIL is to provide a warning if If none of F0061, F0062, or F0063 are raised, the any HV connector is unplugged without the HV problem may be local to connector C790.
  • Page 404 Could you find any defect in Repair as prescribed the HVIL analog circuit? in the in subtree. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Contact Dana for further investigation. Continued on next page...
  • Page 405 Air brake Compressor C790P Air brake Compressor C790P Connector pin Connector pin Pin 3 Pin 4 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.

  • Page 406: Air Brake Compressor No Contact

    3) Resolve CAN communication 3) CAN communication problem. problem. 4) Air brake compressor internal 4) Contact Dana. failure. No Contact fault messages appear on the HMI display and remain while the fault is active. Historical No Contact fault messages can be found in the HMI logs by selecting the MC43[2]log.
  • Page 407 Troubleshooting HMI displays “Brake compressor No contact.” Turn ignition OFF. Inspect fuse F2 in the 24V fuse box C20. Is fuse F2 blown or intermittent? Disconnect connector C202 from air brake compressor. Refer to the connector investigation subtree. Continued on next page...
  • Page 408 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Refer to the CAN Investigation subtree. Investigate CAN A network. Contact Dana for further Is the error still raised? Complete investigation.
  • Page 409 Troubleshooting Disconnect blown fuse F2 from 24V fuse box C20. Replace fuse F2 on 24V fuse box C20. Restart the vehicle. Does fuse F2 blow again Complete during a test drive? Disconnect fuse F2 from 24V fuse box C20. Disconnect connector C202 from air brake compressor.
  • Page 410 Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F2 on 24V fuse box C20. Restart the vehicle. Does fuse F2 blow again Complete during a test drive? Contact Dana for further investigation.

  • Page 411: Air Dryer No Contact

    4) Resolve CAN communication 4) CAN communication problem. problem. 5) iAPU internal failure. Contact Dana. No Contact fault messages appear on the HMI display and remain while the fault is active. Historical No Contact fault messages can be found in the HMI logs by selecting the MC43[2]log.
  • Page 412 Troubleshooting HMI displays “Air Dryer No Contact.” Turn ignition OFF. Inspect fuse F2 in the 24V fuse box C20. Is fuse F2 blown or intermittent? Disconnect connectors C203, C204, and C206 from iAPU. Continued on next page...
  • Page 413 Troubleshooting Continued from previous page Refer to the connector investigation subtree. Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual Remove fuse F2 in order to take continuity measures from inside the fuse box.
  • Page 414 Troubleshooting Continued from previous page Is there any evidence of Defective harness. continuity loss? Replace harness. Refer to the CAN Investigation subtree. Investigate CAN A network. Is the error still raised? Complete Contact Dana for further investigation.
  • Page 415 Troubleshooting Disconnect blown fuse F2 from 24V fuse box C20. Replace fuse F2 on 24V fuse box C20. Restart the vehicle. Does fuse F2 blow again? Complete Turn ignition OFF and disconnect F2 from 24V fuse box C20. Disconnect connector C202 from air brake compressor.
  • Page 416 Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F2 on 24V fuse box C20. Restart the vehicle. Does fuse F2 blow again Complete during a test drive? Contact Dana for further investigation.

  • Page 417: Dcdc System

    Troubleshooting DCDC System The DCDC system accepts high voltage (HV) input which performs the DC-DC conversion, and a control from the ESS and converts it to 24V low voltage (LV) stage. The control stage is powered by 24V DC to charge the two LV batteries, which power the 12V voltage and is connected to the CAN network.
  • Page 418 Troubleshooting F0008 (Fault Reason 1) Error Description Possible Causes Possible Solutions DCDC has detected that the 1) Compatibility problem with 1) Disconnect incompatible DCDC input voltage is too low. aftermarket accessory. accessory. 2) ESS fault. 2) Troubleshoot specific error. 3) HV fuse F8 blown. 3) Replace HV fuse F8.
  • Page 419 Troubleshooting HMI displays or logs Fault code F0008 and DCDC fault reason 1 Does the HMI Refer to error F0026 also display error troubleshooting tree. F0026? Are any aftermarket Disconnect all aftermarket accessories installed accessories and put the vehicle on the vehicle? in ready mode.
  • Page 420 Troubleshooting Continued from previous page WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Disconnect connector C730 from DCDC. Disconnect connector C712 from HV junction box. Refer to connector investigation subtree. Defective connector.
  • Page 421 Inspect fuse F8 in the HV junction box. Is fuse F8 blown or Contact Dana for further intermittent? investigation. Replace fuse F8. DANA must always be informed whenever replacing a fuse in the HV junction box before restarting the truck.
  • Page 422 F0026? troubleshooting tree. Are any aftermarket Disconnect all aftermarket accessories installed accessories and put the vehicle on the vehicle? in ready mode. Does the error occur Potential compatibility issue again? with aftermarket accessories. Contact Dana for further investigation.
  • Page 423 Does the error Does the error disappear more disappear between 3 than 5 minutes and 5 minutes after after entering entering ready mode? ready mode? Complete. If error occurs again later, continue with the next steps. Contact Dana for further investigation.
  • Page 424 Troubleshooting Inspect the LV batteries. Are both batteries Replace faulty battery with a the correct voltage battery that fits the system (12V) and specifications. specification? With a multimeter, measure the voltage between the following points: LV Battery 1 LV Battery 1 Negative terminal Positive terminal LV Battery 2...
  • Page 425 Troubleshooting Continued from previous page Is the voltage Contact Dana for further 24V? investigation. Inspect the battery wiring. Is the negative Incorrect wiring. terminal on battery 2 Wire the batteries according to wired to the positive the instructions provided by the terminal on installation manual.
  • Page 426 Does the error still Potential compatibility issue appear? with aftermarket accessories. Inspect the LV batteries. Turn ignition OFF. Are both batteries the Replace faulty battery with a correct voltage (12V) battery that fits the system and specification? specifications. Contact Dana for further investigation.
  • Page 427 Troubleshooting F0008 (Fault Reason 5) Error Description Possible Causes Possible Solutions DCDC has detected too much 1) Compatibility problem with 1) Disconnect incompatible current being drawn on the LV aftermarket accessory. accessory. network. 2) Overcurrent due to very high 2) Error should self-correct when power steering demand.
  • Page 428 -Inspect all connectors and wires between the two test points defined in the Service Manual of the harness ends. and Diagnostic Guide. Is there any evidence Defective harness. of a short circuit within the Disconnect screw terminal Replace harness. harness? RT008 from the DCDC. Contact Dana for further investigation.
  • Page 429 Troubleshooting F0008 (Fault Reason 6) Error Description Possible Causes Possible Solutions DCDC has detected that the 1) Cooling system problem. 1) Resolve cooling system DCDC internal temperature is too problem. high. HMI displays or logs Fault code F0008 and DCDC fault reason 6 Refer to error F0009 troubleshooting tree.
  • Page 430 Error Description Possible Causes Possible Solutions DCDC has detected an internal 1) DCDC internal failure. 1) Contact Dana. failure which requires support from Dana. HMI displays or logs Fault code F0008 and DCDC fault reason 7 Contact Dana for further investigation.
  • Page 431 CAN problem. network. HMI displays or logs Fault code F0008 and DCDC fault reason 8 Refer to the CAN Investigation subtree. Investigate CAN D network. Is the error still raised? Complete Contact Dana for further investigation.
  • Page 432 Error Description Possible Causes Possible Solutions DCDC has detected an internal 1) DCDC internal failure. 1) Contact Dana. failure which requires support from Dana. HMI displays or logs Fault code F0008 and DCDC fault reason 9 Contact Dana for further investigation.
  • Page 433 Troubleshooting F0008 (Fault Reason 10) Error Description Possible Causes Possible Solutions DCDC has detected a short circuit 1) Compatibility problem with 1) Disconnect incompatible in the LV network. aftermarket accessory. accessory. 2) Overcurrent due to very high 2) Error should self-correct when power steering demand.
  • Page 434 Error Description Possible Causes Possible Solutions DCDC has detected an internal 1) DCDC internal failure. 1) Contact Dana. failure which requires support from Dana. HMI displays or logs Fault code F0008 and DCDC fault reason 11 Contact Dana for further investigation.
  • Page 435 Troubleshooting F0008 (Fault Reason 12) Error Description Possible Causes Possible Solutions DCDC has detected an overload in 1) Compatibility problem with 1) Disconnect incompatible the LV network. aftermarket accessory. accessory. 2) Overcurrent due to very high 2) Error should self-correct when power steering demand.
  • Page 436 Troubleshooting F0008 (Fault Reason 13) Error Description Possible Causes Possible Solutions DCDC has disabled its output 1) Compatibility problem with 1) Disconnect incompatible because the output voltage is too aftermarket accessory. accessory. high. 2) At least one low voltage 2) Replace low voltage battery or battery defective, not to spec, repair battery wiring.
  • Page 437 Troubleshooting F0008 (Fault Reason 14) Error Description Possible Causes Possible Solutions DCDC has detected reverse 1) Compatibility problem with 1) Disconnect incompatible polarity on its output. aftermarket accessory. accessory. 2) At least one low voltage 2) Replace low voltage battery or battery defective, not to spec, repair battery wiring.
  • Page 438 Troubleshooting HMI displays or logs Fault code F0008 and DCDC fault reason 14 Are any aftermarket Disconnect all aftermarket accessories installed accessories and put the vehicle on the vehicle? in ready mode. Does the error still Potential compatibility issue appear? with aftermarket accessories.
  • Page 439 If in doubt, disconnect the wiring and check continuity using a multimeter. Are the batteries Continuity : Resistance is less wired correctly? than or equal to 2ohms. Only disconnect one battery terminal at a time. Contact Dana for further investigation.
  • Page 440 With a multimeter, check for continuity between the following points: Cable Terminal Cable Terminal RT019 RT020 RT019 RT020 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective cable. continuity loss? Replace cable. Contact Dana for further investigation.
  • Page 441 Troubleshooting F0008 (Fault Reason 15) Error Description Possible Causes Possible Solutions VCU has detected a mismatch 1) Compatibility problem with 1) Disconnect incompatible between the DCDC output voltage aftermarket accessory. accessory. and VCU input voltage. 2) At least one low voltage 2) Replace low voltage battery or battery defective, not to spec, repair battery wiring.
  • Page 442 Troubleshooting HMI displays or logs Fault code F0008 and DCDC fault reason 15 Are any aftermarket Disconnect all aftermarket accessories installed accessories and put the vehicle on the vehicle? in ready mode. Does the error still Potential compatibility issue appear? with aftermarket accessories.
  • Page 443 Troubleshooting Continued from previous page Inspect the LV batteries. Are both batteries the Replace faulty battery with a correct voltage (12V) battery that fits the system and specification? specifications. With a multimeter, measure the voltage between the following points: LV Battery 1 LV Battery 1 Negative terminal Positive terminal...
  • Page 444 Pin 65 VCU C651.B 12V fuse box C14 A5 Connector pin Pin 73 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.
  • Page 445 With a multimeter, check for continuity between the following points: Cable Terminal Cable Terminal RT019 RT020 RT019 RT020 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective cable. continuity loss? Replace cable. Contact Dana for further investigation.
  • Page 446 Troubleshooting F0008 (Fault Reason 16) Error Description Possible Causes Possible Solutions VCU has detected a mismatch 1) Compatibility problem with 1) Disconnect incompatible between the DCDC output voltage aftermarket accessory. accessory. and EHPS motor controller input voltage. 2) At least one low voltage 2) Replace low voltage battery or battery defective, not to spec, repair battery wiring.
  • Page 447 Troubleshooting HMI displays or logs Fault code F0008 and DCDC fault reason 16 Are any aftermarket Disconnect all aftermarket accessories installed accessories and put the vehicle on the vehicle? in ready mode. Does the error still Potential compatibility issue appear? with aftermarket accessories.
  • Page 448 Troubleshooting Continued from previous page Inspect the LV batteries. Are both batteries the Replace faulty battery with a correct voltage (12V) battery that fits the system and specification? specifications. With a multimeter, measure the voltage between the following points: LV Battery 1 LV Battery 1 Negative terminal Positive terminal...
  • Page 449 LOTO Switch RT010 EHPS Inverter RT097 Screw terminal Screw terminal Pin 2 RT097 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.
  • Page 450 With a multimeter, check for continuity between the following points: Cable Terminal Cable Terminal RT019 RT020 RT019 RT020 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective cable. continuity loss? Replace cable. Contact Dana for further investigation.
  • Page 451 Fault code F0009 Does the HMI also Refer to the corresponding display error F0059 or troubleshooting tree. F0060? Does the HMI also Contact Dana for further display error F0008 investigation. (DCDC fault reason 11)? Refer to the cooling system investigation subtree.
  • Page 452 Troubleshooting F0144 - Potential High Voltage Hazard! DCDC HVIL Fault Error Description Possible Causes Possible Solutions DCDC has detected a discontinuity 1) HV connector unplugged. 1) Plug in HV connector. in the high voltage interlock loop (HVIL). 2) Defective HV connector or 2) Replace HV harness.
  • Page 453 Troubleshooting HMI displays or logs Fault code F0144 Does the HMI also Check the HMI for other faults. display error F0061, F0062, or F0063? WARNING: Electrical hazard. Turn ignition OFF. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 454 DCDC C730P DCDC C730P Connector pin Connector pin Pin 3 Pin 4 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.
  • Page 455 Troubleshooting WARNING: Electrical hazard. Turn ignition OFF. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect connector C730 on DCDC and connector C712 on HV junction box. Is connector C730 or Plug it in and restart the vehicle. C712 unplugged? Disconnect connector C730 from DCDC.
  • Page 456 HV Jct Box C712P HV Jct Box C712P Connector pin Connector pin Pin 3 Pin 4 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Contact Dana for further investigation.

  • Page 457: Dcdc No Contact

    Troubleshooting DCDC no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) Blown 24V fuse F3. 1) Replace 24V fuse F3. message from the DCDC within a specified time interval. 2) Blown 24V fuse F12. 2) Replace 24V fuse F12.
  • Page 458 Troubleshooting HMI displays “DCDC No contact.” Does the HMI also Refer to error F0008 (DCDC fault display error F0008 reason 8) troubleshooting tree. (DCDC fault reason WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide.
  • Page 459 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: DCDC C84 24V fuse box C20...
  • Page 460 Troubleshooting Continued on next page Is the error still being raised on further key ON Complete cycles? Contact Dana for further investigation.
  • Page 461 Troubleshooting Complete Replace fuse F3 on 24V fuse box Disconnect blown fuse F3 from Did fuse F3 blow again C20. 24V fuse box C20. during test drive? Restart the vehicle. Turn ignition OFF and Disconnect connector C84 from disconnect F3 from 24V fuse DCDC.
  • Page 462 Is there any evidence of a short Defective harness. circuit within the Replace harness. harness? Replace fuse F3 on 24V fuse box C20. Restart the vehicle. Did fuse F3 blow again Complete during test drive? Contact Dana for further investigation.
  • Page 463 Troubleshooting Complete Replace fuse F12 on 24V fuse Did fuse F12 blow Disconnect blown fuse F12 from box C20. again during test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Disconnect connector C84 from disconnect F12 from 24V fuse DCDC.
  • Page 464 Is there any evidence of a short Defective harness. circuit within the Replace harness. harness? Replace fuse F12 on 24V fuse box C20. Restart the vehicle. Did fuse F12 blow again Complete during test drive? Contact Dana for further investigation.

  • Page 465: Low Voltage Distribution System

    Troubleshooting Low Voltage Distribution System The low voltage distribution system distributes 12V MPDM and 24V power throughout the vehicle to power The Multiplex Power Distribution Module (MPDM) onboard equipment and accessories. provides a 12V output to power equipment throughout the vehicle. The MPDM outputs are fused Component Descriptions and in some cases are controlled by relays.
  • Page 466 Troubleshooting F0064 to F0079 - Check Powertrain Fuse #N Error Description Possible Causes Possible Solutions MPDM has detected that MPDM 1) LV supply problem. 1) Troubleshoot specific error. fuse #N has failed. 2) Blown MPDM fuse #N. 2) Replace MPDM fuse #N. 3) MPDM internal failure.
  • Page 467 Troubleshooting Connector C12 (gray) Connector C3 Connector C22 Connector C10 Connector C23 Connector C11 (black)
  • Page 468 Troubleshooting Connector C44 Connector C54 Connector C45 Connector C661 Connector C53...
  • Page 469 Troubleshooting HMI displays or logs Fault code F0064 to F0079. Are multiple powertrain Does the HMI also fuse error messages display F0095 ? displayed on the HMI? Refer to the MPDM Table to Refer to error F0095 determine which fuse to check. troubleshooting tree.
  • Page 470 Troubleshooting Continued from previous page Did the fuse blow Reconnect the harness to the device. again? Turn ON the ignition to ready mode. Turn the ignition OFF. Inspect the associated fuse again. Refer to the connector investigation subtree. Did the fuse blow Complete again? Defective device.
  • Page 471 Troubleshooting Continued from previous page Refer to the MPDM Table. Reconnect the connector to the corresponding subsystem. With a multimeter, check for short circuit between the following points: MPDM Ground Connector Fuse pin GND strip1 -LV short: Resistance measurement is less than 100k- ohms.
  • Page 472 Troubleshooting Disconnect connector C10 from MPDM. Refer to the connector investigation subtree. Is there any problem with the connector integrity? With a multimeter, measure the voltage between the following points: MPDM C10 MPDM C10 Defective connector. Connector Connector Replace the connector as described in the “Wire Harness Connector Identification, Pin 1 Pin 3...
  • Page 473 Troubleshooting Continued from previous page Is there any problem with the connector integrity? With a multimeter, check for continuity between the following points: MPDM C10 MPDM C12 Connector Connector Defective connector. Replace the connector as described in the Pin 1 Pin A “Wire Harness Connector Identification, MPDM C10...
  • Page 474 Troubleshooting F0080 to F0087 - Check Powertrain Relay #N Error Description Possible Causes Possible Solutions MPDM has detected that MPDM 1) LV supply problem. 1) Troubleshoot specific error. relay #N has failed. 2) Defective MPDM relay #N. 2) Replace MPDM relay #N. 3) Blown MPDM fuse.
  • Page 475 Troubleshooting Connector C12 (gray) Connector C3 Connector C22 Connector C10 Connector C23 Connector C11 (black)
  • Page 476 Troubleshooting Connector C44 Connector C54 Connector C45 Connector C661 Connector C53...
  • Page 477 Troubleshooting HMI displays or logs Fault code F0080 to F0087 Are multiple powertrain fuse or relay Does the HMI also display error messages displayed F0095 ? on the HMI? Refer to the MPDM Table to Refer to error F0095 determine which fuse and relay troubleshooting tree.
  • Page 478 Troubleshooting Disconnect connector C10 from MPDM. Refer to the connector investigation subtree. Is there any problem with the connector integrity? With a multimeter, measure the voltage between the following points: MPDM C10 MPDM C10 Defective connector. Connector Connector Replace the connector as described in Pin 1 Pin 3 the “Wire Harness Connector...
  • Page 479 Troubleshooting Continued from previous page Is there any problem with the connector integrity? With a multimeter, check for continuity between the following points: MPDM C10 MPDM C12 Connector Connector Defective connector. Replace the connector as described in the Pin 1 Pin A “Wire Harness Connector Identification, Location, and Service Chart”...

  • Page 480: Power Steering System

    The and steering box connected by hydraulic lines. power stage converts 24V DC input from the LV These items are not supplied by Dana and are distribution network to three-phase AC output to outside the scope of this troubleshooting guide.
  • Page 481 Note: When referring to the TM4 power message from the EHPS motor controller. Result steering troubleshooting guide, through use of the Dana TM4 EHPS Motor Controller MI06 Troubleshooting Guide. • “Main harness connector” or “Connector C1” correspond to connector C34 on the EHPS service codes: 2407, 2801, 2802, 2803, 3402, PACCAR vehicle.
  • Page 482 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 0101 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Defective EHPS motor 1) Replace EHPS motor that the power steering system is controller. controller. not operable. HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 0101...
  • Page 483 HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 2402/2403/2404/2405/2406 Refer to the Dana TM4 When troubleshooting these EHPS EHPS Motor Controller MI06 Troubleshooting service codes, the technician is instructed Guide for code 2402, 2403, 2404, 2405, 2406.* to check the main contactor.
  • Page 484 HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 3602 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 3602, the technician is instructed to check Troubleshooting Guide for code 3602.
  • Page 485 Troubleshooting Continued from previous page Does the hydraulic pump Replace EHPS pump and connection to the EHPS motor motor assembly. seem faulty? Replace EHPS pump and Does the pump seem motor assembly. unable to turn properly? If no external system was found responsible for the failure and the root cause couldn’t be found in the TM4 troubleshooting guide then the EHPS motor controller is considered defective.
  • Page 486 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 3604, 3707 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering that the power steering system is steering troubleshooting guide.
  • Page 487 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 3604/3707 Refer to the Dana TM4 EHPS Motor Controller MI06 When troubleshooting fault reason 3604, Troubleshooting Guide for codes 3604, 3707. 3707, the technician is instructed to check the LV distribution network for root causes.
  • Page 488 Troubleshooting Continued from previous page Disconnect connector C34 from EHPS motor controller. Refer to connector integrity inspection subtree. Defective connector. Is there any Replace the connector as described in the “Wire problem with the Harness Connector Identification, Location, and connector Service Chart”...
  • Page 489 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code Fault Reason 3610 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering that the power steering system is steering troubleshooting guide.
  • Page 490 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 3610 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 3610, the technician is instructed to check the Troubleshooting Guide for code 3610 LV distribution network for root causes.
  • Page 491 Troubleshooting Continued from previous page Disconnect connector C34 from EHPS motor controller. Refer to connector integrity inspection subtree. Defective connector. Is there any Replace the connector as described in the “Wire problem with the Harness Connector Identification, Location, and connector Service Chart”...
  • Page 492 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 3703, 3704 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering that the power steering system is steering troubleshooting guide.
  • Page 493 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 3703/3704 Refer to the Dana TM4 EHPS Motor Controller MI06 When troubleshooting EHPS service code 3703, Troubleshooting Guide for code 3703, 3704. 3704, the technician is instructed to check the LV distribution network for root causes.
  • Page 494 Troubleshooting Continued from previous page Disconnect connector C34 from EHPS motor controller. Refer to the connector investigation subtree. Defective connector. Replace the connector as described in the “Wire Is there any problem with Harness Connector Identification, Location, and the connector integrity? Service Chart”...
  • Page 495 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 3802 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering that the power steering system is steering troubleshooting guide.
  • Page 496 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 3802 Refer to the Dana TM4 EHPS Motor Controller MI06 When troubleshooting EHPS service code Troubleshooting Guide for code 3802. 3802, the technician is instructed to check the LV distribution network for root causes.
  • Page 497 Troubleshooting Continued from previous page Disconnect connector C34 from EHPS motor controller. Refer to the connector investigation subtree. Defective connector. Replace the connector as described in the “Wire Is there any problem with Harness Connector Identification, Location, and the connector integrity? Service Chart”...
  • Page 498 Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 499 Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 500 3) Ambient temperature exceeds 50°C. HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 5102 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 5102, the technician is instructed to check Troubleshooting Guide for code 5102.
  • Page 501 Does the pump seem motor assembly. unable to turn properly? Has error code F0059, F0060, Contact Dana for further investigation. Make sure to F0020, F0000, F0096 or F0008 only use aftermarket accessories compatible with the been raised configuration of the truck.
  • Page 502 3) Ambient temperature exceeds 50°C. HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 5201 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 5201, the technician is instructed to check Troubleshooting Guide for code 5201 the hydraulic system for root causes.
  • Page 503 Troubleshooting Continued from previous page Does the hydraulic pump Replace EHPS pump and connection to the EHPS motor motor assembly. seem faulty? Replace EHPS pump and Does the pump seem motor assembly. unable to turn properly? If no external system was found responsible for the failure and the root cause couldn’t be found in the TM4 troubleshooting guide then the EHPS motor controller is considered defective.
  • Page 504 3) Ambient temperature exceeds 50°C. HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 5202 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 5202, the technician is instructed to check Troubleshooting Guide for code 5202.
  • Page 505 Troubleshooting Continued from previous page Does the hydraulic pump Replace EHPS pump and connection to the EHPS motor motor assembly. seem faulty? Replace EHPS pump and Does the pump seem motor assembly. unable to turn properly? If no external system was found responsible for the failure and the root cause couldn’t be found in the TM4 troubleshooting guide then the EHPS motor controller is considered defective.
  • Page 506 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 5401 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering a problem resulting in possible steering troubleshooting guide. troubleshooting guide.
  • Page 507 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 5401 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 5401, the technician is instructed to check the Troubleshooting Guide for code 5401.
  • Page 508 Troubleshooting Continued from previous page Disconnect connector C34 from EHPS motor controller. Refer to the connector investigation subtree. Defective connector. Replace the connector as described in the “Wire Is there any problem with Harness Connector Identification, Location, and the connector integrity? Service Chart”...
  • Page 509 Troubleshooting F0010, F0011, F0012, F0013, or F0014 EHPS service code 5402 Error Description Possible Causes Possible Solutions The EHPS motor controller detects 1) Causes covered in TM4 power 1) Refer to TM4 power steering that the power steering system is steering troubleshooting guide.
  • Page 510 Troubleshooting HMI displays or logs Fault code F0010/F0011/F0012/F0013/F0014 and EHPS service code 5402 Refer to the Dana TM4 When troubleshooting EHPS service code EHPS Motor Controller MI06 5402 the technician is instructed to check Troubleshooting Guide for code 5402. the main contactor.
  • Page 511 Troubleshooting Continued from previous page Is there any visible Defective wiring. signs of degradation on Replace wiring. the wires? Disconnect connector C34 from EHPS motor controller. Refer to the connector investigation subtree. Defective connector. Replace the connector as described in the “Wire Is there any problem with Harness Connector Identification, Location, and the connector integrity?
  • Page 512 Troubleshooting F0132 - Low Voltage system fault Error Description Possible Causes Possible Solutions EHPS motor controller is unable to 1) EHPS motor controller, DCDC, 1) Troubleshoot specific error. start because of a problem with or LV distribution fault. the LV network. 2) Replace EHPS motor 2) EHPS motor controller internal controller.
  • Page 513 Troubleshooting Power Steering no contact Error Description Possible Causes Possible Solutions The VCU has not received any 1) Blown 24V fuse F10. 1) Replace 24V fuse F10. CAN message from the EHPS motor controller within a specified 2) Blown 12V fuse F13. 2) Replace 12V fuse F13.
  • Page 514 Troubleshooting Connector C676 Circuit73 Connector C651.B...
  • Page 515 Troubleshooting HMI displays “Power steering No contact” Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree.
  • Page 516 Troubleshooting Continued from previous page Is the voltage over Defective EHPS motor controller. 24V? Replace EHPS motor controller. Defective connector. Replace the connector as Is there any problem with described in the “Wire Harness the connector integrity? Connector Identification, Turn ignition OFF. Location, and Service Chart”...
  • Page 517 Is there any proof of a Defective harness. continuity loss? Replace harness. Refer to relay investigation subtree. Investigate relay K015. Is there any evidence Defective relay. of a defect between the Replace relay. pins of the relay? Contact Dana for further investigation.
  • Page 518 Troubleshooting Complete Replace fuse F13 on 24V fuse Disconnect blown fuse F13 from Did fuse F13 blow again box C20. 24V fuse box C20. during test drive? Restart the vehicle. Disconnect connector C34 from Turn ignition OFF and Refer to the connector EHPS motor controller.
  • Page 519 Is there any evidence of a Defective relay. defect between the pins of Replace relay. the relay? Replace fuse F13 on 24V fuse box C20. Restart the vehicle. Did fuse F13 blow again Complete during test drive? Contact Dana for further investigation.
  • Page 520 Troubleshooting Complete Replace fuse F10 on 12V fuse Did fuse F10 Disconnect blown fuse F10 from box C14. blow again during 12V fuse box C14. Restart the vehicle. test drive? Turn ignition OFF and Refer to the connector Disconnect connector C34 from disconnect F10 from 12V fuse investigation subtree.
  • Page 521 Is there any evidence of a Defective relay. defect between the pins of Replace relay. the relay? Replace fuse F10 on 12V fuse box C14. Restart the vehicle. Did fuse F10 blow again Complete during test drive? Contact Dana for further investigation.

  • Page 522: Hvac System

    The same blower is used for heating and surrounding atmosphere. The working fluid is R- cooling. It is not supplied by Dana and is outside the 134a refrigerant. scope of this troubleshooting guide.
  • Page 523 Troubleshooting F0053 (Fault Reason 1, 2, 4, 5, 8) Error Description Possible Causes Possible Solutions Cabin heater has reported an 1) Cabin heater fault. 1) Troubleshoot specific error. internal error. 2) Cabin heater internal failure. 2) Replace cabin heater. The technician should check for overheating (F0133) Otherwise, the heater needs to be replaced.
  • Page 524 Troubleshooting F0053 (Fault Reason 3) Error Description Possible Causes Possible Solutions Cabin heater reported an 1) A/C fault. 1) Troubleshoot specific error. overcurrent condition. Blown HV fuse F5. 2) Replace HV fuse F5. 3) Cabin heater internal failure. 3) Replace cabin heater. An overcurrent condition may occur if the A/C compressor is defective.
  • Page 525 Check the fuse F5 in the HV junction box WARNING: Electrical hazard. Follow Safety Warnings and High Replace the fuse and inform Is fuse F5 Voltage Shutdown Procedures DANA before restarting the blown or defined in the Service Manual truck. intermittent? and Diagnostic Guide. Defective heater.
  • Page 526 Troubleshooting F0053 (Fault Reason 6, 7) Error Description Possible Causes Possible Solutions Cabin heater has reported an 1) Heater pump fault. 1) Troubleshoot specific error. overtemperature condition. 2) Low fluid level, leak, 2) Resolve low fluid level, leak, obstruction, or air lock in obstruction, or air lock in heating circuit.
  • Page 527 Troubleshooting F0054 - Limited cabin heating Error Description Possible Causes Possible Solutions The cabin heater has reported a 1) ESS fault. 1) Troubleshoot specific error. problem which may result in reduced heating performance. 2) Blown 12V fuse F13. 2) Replace 12V fuse F13. 3) Defective LV harness or 3) Replace LV connector or connector.
  • Page 528 Troubleshooting HMI displays or logs Fault code F0054 Does the HMI also Refer to error F0026 display error troubleshooting tree. F0026? Place the vehicle in accessory mode. Is error F0054 Troubleshoot the high voltage. still raised? Add the correct section here. WARNING: Electrical hazard.
  • Page 529 Troubleshooting Continued from previous page Is fuse F13 blown or intermittent? Disconnect connector C73 from heater. Remove fuse F13 in order to take continuity measures from inside the fuse box. Refer to connector investigation subtree. Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and...
  • Page 530 Troubleshooting Continued from previous page Is there any evidence of Defective harness. continuity loss? Replace harness. Disconnect connector C721 from heater. Disconnect connector C709 from HV junction box. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures Refer to connector defined in the Service Manual investigation subtree.
  • Page 531 Troubleshooting Continued from previous page Is there any evidence of Defective harness. continuity loss? Replace harness. Connect connector C709 to HV junction box. Observing proper safety precautions, open the HV junction box. Inspect fuse F5 in the HV junction box. Defective heater.
  • Page 532 Defective harness. of a short circuit within Replace harness. the harness? Replace fuse F5. Always inform DANA when replacing a fuse in the HV junction box. Close HV junction box and restart the vehicle. Does fuse F5 blow Defective heater.
  • Page 533 Troubleshooting Disconnect blown fuse F13 from 12V fuse box C14. Replace fuse F13 on 12V fuse box C14. Restart the vehicle. Did fuse F13 blow again Complete during a test drive? Turn ignition OFF and disconnect F13 from 12V fuse box C14.
  • Page 534 Troubleshooting Continued from previous page With a multimeter, check for short circuit between the following points: C73 Heater Ground Connector pin Pin 1 Ground -LV short: Resistance measurement is less than 100k- ohms. -Inspect all connectors and wires between the two test points of the harness ends.
  • Page 535 Troubleshooting F0055 - Cabin heating system fault Error Description Possible Causes Possible Solutions The cabin heater pump has 1) Low fluid level or leak in 1) Repair and/or refill heating reported a dry run condition. heating circuit. circuit. 2) Cabin heater pump internal 2) Replace cabin heater pump.
  • Page 536 Troubleshooting F0105 - Limited Cabin Cooling Error Description Possible Causes Possible Solutions Condenser fan 1 (bottom fan) or 1) Condenser fan 1 or 2 1) Clear obstruction or replace condenser fan 2 (top fan) has obstructed or damaged. fan. reported a fault. 2) Voltage problem on LV 2) Troubleshoot specific error.
  • Page 537 Troubleshooting HMI displays or logs Fault code F0105 Does the HMI also display F0008, F0095, Refer to the corresponding error or condenser fan no troubleshooting tree. contact? Visually inspect condenser fan 1 and 2. Is either fan damaged, obstructed, or otherwise Clear obstruction or replace fan.
  • Page 538 Troubleshooting Continued from previous page Is fuse F4 blown or intermittent? Inspect fuse F14 in the 24V fuse box C20. Is fuse F14 blown or intermittent? Disconnect connector C82 from condenser fan 2. Remove fuse F4 and F14 in order to take continuity measures from inside the fuse box.
  • Page 539 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: Condenser fan 2 C82 24V fuse box C20...
  • Page 540 Troubleshooting Continued from previous page Is fuse F5 blown or intermittent? Inspect fuse F15 in the 24V fuse box C20. Is fuse F15 blown or intermittent? Disconnect connector C89 from condenser fan 1. Remove fuse F5 and F15 in order to take continuity measures from inside the fuse box.
  • Page 541 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: Condenser fan 1 C89 24V fuse box C20 Connector pin Terminal Pin 1 Condenser fan 1 C89 24V fuse box C20 Connector pin Terminal Pin 6 Condenser fan 1 C89 Ground Connector pin...
  • Page 542 Troubleshooting Complete Replace fuse F4 on 24V fuse box Disconnect blown fuse F4 from Did fuse F4 blow again C20. 24V fuse box C20. during a test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect connector C82 from disconnect F4 from 24V fuse box investigation subtree.
  • Page 543 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F4 on 24V fuse box C20. Restart the vehicle. Did fuse F4 blow again Complete during a test drive? Defective condenser fan 2.
  • Page 544 Troubleshooting Complete Replace fuse F14 on 24V fuse Did fuse F14 blow Disconnect blown fuse F14 from box C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C82 from disconnect F14 from 24V fuse investigation subtree.
  • Page 545 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F14 on 24V fuse box C20. Restart the vehicle. Did fuse F14 blow again during a test Complete drive? Defective condenser fan 2.
  • Page 546 Troubleshooting Complete Replace fuse F5 on 24V fuse box Did fuse F5 blow Disconnect blown fuse F5 from C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C89 from disconnect F5 from 24V fuse box investigation subtree.
  • Page 547 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F5 on 24V fuse box C20. Restart the vehicle. Did fuse F5 blow again during a test Complete drive? Defective condenser fan 1.
  • Page 548 Troubleshooting Complete Replace fuse F15 on 24V fuse Did fuse F15 blow Disconnect blown fuse F15 from box C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C89 from disconnect F15 from 24V fuse investigation subtree.
  • Page 549 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F15 on 24V fuse box C20. Restart the vehicle. Did fuse F15 blow again during a test Complete drive? Defective condenser fan 1.
  • Page 550 3) A/C compressor fault If no other code appears, the technician should 4) Low refrigerant pressure in A/C system contact Dana to resolve a possible software error. This can result in reduced performance of the defrost function. HMI displays or logs...
  • Page 551 Troubleshooting F0133 - Cabin heater over temperature Error Description Possible Causes Possible Solutions The cabin heater has reported an 1) Heater pump fault. 1) Troubleshoot specific error. over temperature condition. 2) Low fluid level, leak, 2) Resolve low fluid level, leak, obstruction, or air lock in obstruction, or air lock in heating circuit.
  • Page 552 Troubleshooting F0134 - Cabin heating system fault Error Description Possible Causes Possible Solutions The heater pump has reported a 1) Obstruction or air lock in 1) Resolve obstruction or air lock stall condition. heating circuit. in heating circuit. 2) Heater pump internal failure. 2) Replace heater pump.
  • Page 553 Troubleshooting F0135 - Cabin heating system fault Error Description Possible Causes Possible Solutions The heater pump has reported an 1) Cabin heater fault. 1) Troubleshoot specific error. over temperature condition. 2) Low fluid level, leak, 2) Resolve low fluid level, leak, obstruction, or air lock in obstruction, or air lock in heating circuit.
  • Page 554 Troubleshooting F0136 - Cabin heating system fault Error Description Possible Causes Possible Solutions The heater pump has reported a 1) LV distribution system fault. 1) Troubleshoot specific error. low speed condition. 2) Blown 12V fuse F15. 2) Replace 12V fuse F15. 3) Loss of continuity due to 3) Replace LV connector or defective LV connector or...
  • Page 555 Troubleshooting HMI displays or logs Fault code F0136 Does the HMI also Refer to the corresponding error display error F0008 troubleshooting tree. or F0095? If the heater was used recently, wait for components to cool down. Is the fluid in the Drain and flush heating circuit.
  • Page 556 Troubleshooting Continued from previous page Is the pump outlet Clear obstruction, reconnect visibly obstructed? hose, and refill fluid as needed. Bleed the heater pump by using the service interface to activate the pump. Does fluid flow out of Check for obstructions between the outlet when the the reservoir and pump.
  • Page 557 Troubleshooting Continued from previous page Is the problem Complete resolved? Disconnect the heating circuit one section at a time and check for obstructions. Is the heating circuit Clear obstruction, reconnect obstructed? hoses, and refill fluid as needed. Defective heater pump. Replace heater pump.
  • Page 558 Troubleshooting WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect fuse F15 in the 12V fuse box C14. Is fuse F15 blown or intermittent? Disconnect connector C74 from heater pump. Disconnect connector C651.B from VCU.
  • Page 559 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: 12V fuse box C14 Connector pin...
  • Page 560 Troubleshooting Complete Replace fuse F15 on 12V fuse Disconnect blown fuse F15 from Did fuse F15 blow again box C14. 12V fuse box C14. during a test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect connector C74 from disconnect F15 from 12V fuse investigation subtree.
  • Page 561 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F15 on 12V fuse box C14. Restart the vehicle. Did fuse F15 blow again Complete during a test drive? Defective heater pump.
  • Page 562 Troubleshooting F0141 - Low A/C refrigerant pressure Error Description Possible Causes Possible Solutions The VCU has detected low 1) A/C compressor fault. 1) Troubleshoot specific error. refrigerant pressure in the air conditioner. 2) Leak or low refrigerant level. 2) Repair and/or recharge A/C system.
  • Page 563 Troubleshooting HMI displays or logs Fault code F0141 Does the HMI also display A/C compressor Refer to the corresponding fault or A/C compressor error troubleshooting tree. no contact? Locate the A/C system and check the refrigerant pressure. Is the refrigerant Inspect refrigerant lines for any pressure lower than evidence of a leak.
  • Page 564 Pin 2 Pin E - Continuity : Resistance is less than or equal to 2ohms. Defective harness. Is there any evidence of Replace the pressure sensor. Replace harness. continuity loss? Is error F0141 still Complete raised? Contact DANA for further investigation.
  • Page 565 Troubleshooting F0142 - Potential High Voltage Hazard! HVAC HVIL Fault Error Description Possible Causes Possible Solutions The A/C compressor has detected 1) HV connector unplugged. 1) Connect HV connector. a discontinuity in the high voltage interlock loop (HVIL). 2) Defective HV connector or 2) Replace HV harness.
  • Page 566 Troubleshooting HMI displays or logs Fault code F0142 Does the HMI also display F0061, F0062, or F0063? Turn ignition OFF. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect connector C729 on A/C compressor.
  • Page 567 Troubleshooting Continued from previous page Is connector C729 Plug it in and restart the vehicle. unplugged? Disconnect connector C729 from Refer to the connector A/C compressor. investigation subtree. Defective connector. Is there any problem with Replace harness. the connector integrity? With a multimeter, check for continuity between the following points: AC compressor C729P...
  • Page 568 Troubleshooting Turn ignition OFF. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect connector C729 on A/C compressor and connector C710 on HV junction box. Is connector C729 or C710 Plug it in and restart the vehicle.
  • Page 569 Troubleshooting Continued from previous page Refer to the connector investigation subtree. Is there any problem with Defective connector. the connector integrity? Replace harness. With a multimeter, check for continuity between the following points: AC compressor C729P AC compressor C729P Connector pin Connector pin Pin 3 Pin 4...
  • Page 570 Possible Solutions Not currently implemented. 1) VCU software error. 1) Contact Dana. The VCU has detected a discontinuity in the high voltage interlock loop (HVIL) at the heater. HMI displays or logs Fault code F0143 Contact DANA for further investigation.
  • Page 571 Troubleshooting F0158 - A/C compressor fault Error Description Possible Causes Possible Solutions The A/C compressor has reported 1) ESS fault. 1) Troubleshoot specific error. a fault condition. 2) Defective LV connector or 2) Replace LV connector or harness. harness per Service Manual. 3) Blown HV fuse F6.
  • Page 572 Troubleshooting HMI displays or logs Fault code F0158 Does the HMI Refer to F0026 troubleshooting also display error tree. F0026? Disconnect connector C71 from A/C compressor. Refer to the connector investigation subtree. Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart”...
  • Page 573 Troubleshooting Continued from previous page Is the voltage Defective harness. approximately 12V? Replace harness. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Disconnect connector C729 from A/C compressor. Disconnect connector C710 from HV junction box.
  • Page 574 Investigate CAN A network. Replace fuse F6. Close HV junction box and restart the vehicle. Contact Dana for further Always call DANA to let them know when a fuse investigation. in the HV junction box is replaced. Does fuse F6 blow...
  • Page 575 Troubleshooting Continued from previous page With a multimeter, check for short circuit between the following points: AC compressor C729P Ground Connector pin Pin 2 Ground -HV short: Resistance measurement is less than 350k-ohms. -Inspect all connectors and wires between the two test points of the harness ends.
  • Page 576 Troubleshooting Radiator Fan 01 no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from condenser fan 1 problem. (bottom fan) within a specified time 2) Blown 24V fuse F5. interval.
  • Page 577 Troubleshooting HMI displays “No contact with condenser fan 1.” Inspect fuse F5 in the 24V fuse Is fuse F5 blown or box C20. intermittent? Inspect fuse F15 in the 24V fuse box C20. Is fuse F15 blown or intermittent? Disconnect connector C89 from condenser fan 1.
  • Page 578 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: Condenser fan 1 C89 24V fuse box C20 Connector pin Terminal Pin 1 Condenser fan 1 C89 24V fuse box C20 Connector pin Terminal Pin 6 Condenser fan 1 C89 Ground Connector pin...
  • Page 579 Troubleshooting Complete Replace fuse F5 on 24V fuse box Did fuse F5 blow Disconnect blown fuse F5 from C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C89 from disconnect F5 from 24V fuse box investigation subtree.
  • Page 580 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F5 on 24V fuse box C20. Restart the vehicle. Did fuse F5 blow again during a test Complete drive? Defective condenser fan 1.
  • Page 581 Troubleshooting Complete Replace fuse F15 on 24V fuse Did fuse F15 blow Disconnect blown fuse F15 from box C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C89 from disconnect F15 from 24V fuse investigation subtree.
  • Page 582 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F15 on 24V fuse box C20. Restart the vehicle. Did fuse F15 blow again during a test Complete drive? Defective condenser fan 1.
  • Page 583 Troubleshooting Radiator Fan 02 no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from condenser fan 2 problem. (top fan) within a specified time 2) Blown 24V fuse F4. interval.
  • Page 584 Troubleshooting HMI displays “No contact with condenser fan 2.” Inspect fuse F4 in the 24V fuse Is fuse F4 blown or box C20. intermittent? Inspect fuse F14 in the 24V fuse box C20. Is fuse F14 blown or intermittent? Disconnect connector C82 from condenser fan 2.
  • Page 585 Troubleshooting Continued from previous page Refer to the connector investigation subtree. Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: Condenser fan 2 C82...
  • Page 586 Troubleshooting Continued from previous page Is there any evidence of Defective harness. continuity loss? Replace harness. Refer to the CAN investigation subtree. Investigate CAN C network. Is the error still raised? Complete Defective condenser fan 2. Replace condenser fan 2.
  • Page 587 Troubleshooting Complete Replace fuse F4 on 24V fuse box Disconnect blown fuse F4 from Did fuse F4 blow again C20. 24V fuse box C20. during a test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect connector C82 from disconnect F4 from 24V fuse box investigation subtree.
  • Page 588 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F4 on 24V fuse box C20. Restart the vehicle. Did fuse F4 blow again Complete during a test drive? Defective condenser fan 2.
  • Page 589 Troubleshooting Complete Replace fuse F14 on 24V fuse Did fuse F14 blow Disconnect blown fuse F14 from box C20. again during a test 24V fuse box C20. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C82 from disconnect F14 from 24V fuse investigation subtree.
  • Page 590 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F14 on 24V fuse box C20. Restart the vehicle. Did fuse F14 blow again during a test Complete drive? Defective condenser fan 2.

  • Page 591: A/C Compressor No Contact

    Troubleshooting A/C Compressor no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from the A/C compressor problem. within a specified time interval. 2) Blown 12V fuse F12. 2) Replace 12V fuse F12.
  • Page 592 Troubleshooting HMI displays “A/C Compressor No contact.” WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect fuse F12 in the 12V fuse box C14. Is fuse F12 blown or intermittent? Disconnect connector C71 from A/C compressor.
  • Page 593 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: AC compressor C71 12V fuse box C14...
  • Page 594 Troubleshooting Complete Replace fuse F12 on 12V fuse Did fuse F12 blow Disconnect blown fuse F12 from box C14. again during a test 12V fuse box C14. Restart the vehicle. drive? Turn ignition OFF and Refer to the connector Disconnect connector C71 from disconnect F12 from 12V fuse investigation subtree.
  • Page 595 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F12 on 12V fuse box C14. Restart the vehicle. Did fuse F12 blow again during a test Complete drive? Defective A/C compressor.

  • Page 596: Cabin Heater No Contact

    Troubleshooting Cabin Heater no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from the heater within a problem. specified time interval. 2) Blown 12V fuse F13. 2) Replace 12V fuse F13.
  • Page 597 Troubleshooting HMI displays “Cabin Heater No Contact.” WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect fuse F13 in the 12V fuse box C14. Is fuse F13 blown or intermittent? Disconnect connector C73 from heater.
  • Page 598 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: Heater C73 12V fuse box C14...
  • Page 599 Troubleshooting Continued from previous page Is there any evidence of Defective harness. continuity loss? Replace harness. Refer to the CAN investigation subtree. Investigate CAN C network. Is the error still raised? Complete Contact Dana for further investigation.
  • Page 600 Troubleshooting Disconnect blown fuse F13 from 12V fuse box C14. Replace fuse F13 on 12V fuse box C14. Restart the vehicle. Did fuse F13 blow again Complete during a test drive? Turn ignition OFF and disconnect F13 from 12V fuse box C14.
  • Page 601 Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F13 on 12V fuse box C14. Restart the vehicle. Did fuse F13 blow again Complete during a test drive? Contact Dana for further investigation.

  • Page 602: Vcu-Hmi System

    Troubleshooting VCU-HMI System or maintenance operator to perform vehicle control Component descriptions functions as well as access operational data and error messages. It is powered by 12V low voltage and communicates with the VCU through the CAN network. The Vehicle Control Unit (VCU) is the main processing unit which monitors and controls most of Supervisory Controller the systems and equipment on the vehicle.
  • Page 603 BMS fault). If error F0050 appears alone, the technician should • Supervisory controller requests shutdown. contact Dana for further investigation. HMI displays or logs Fault code F0050 “Turn on Hazard Lights!” Does the HMI also...
  • Page 604 (BMS, Traction inverter, or VCU). instances of errors F0051 or F0052 should be referred to Dana for specialized troubleshooting. HMI displays or logs Fault code F0051/F0052 and FSVCU mitigation reason “X’’...
  • Page 605 Error Description Possible Causes Possible Solutions VCU has detected a malfunction in 1) HV distribution internal error. 1) Contact Dana. the HV distribution system which requires support from Dana. HMI displays or logs Fault code F0057 Contact Dana for further investigation.
  • Page 606 Troubleshooting F0058 - Emergency service cut loop is open. Error Description Possible Causes Possible Solutions VCU has detected that the cut loop 1) Cut loop broken or faulty cut 1) Replace cut loop wiring. is broken. loop wiring. 2) Troubleshoot specific error. 2) Cut loop bundle is cut or damaged.
  • Page 607 Troubleshooting Connector C367S (socket) Connector C367P (pin) Connector C676 Circuit73 Connector C651.B...
  • Page 608 Troubleshooting HMI displays or logs Fault code F0058 Has the cut loop been Contact Dana for further cut previously? investigation. Turn ignition OFF. Is fuse F20 on 12V fuse box Does the HMI also display Refer to the specific error...
  • Page 609 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: MPDM C11 C93P Connector pin Connector pin Pin A Pin 7 Pin D Pin 5 MPDM C11 C40S Connector pin Connector pin Pin G Pin 12 C93S Connector pin Connector pin...
  • Page 610 Troubleshooting Continued from previous page With a multimeter, check for continuity between the following points: VCU C651.B C676P Connector Connector Pin 41 Pin 17 C91S C40S Connector Connector Pin 17 Pin 32 C40P C367S Connector Connector Pin 32 Pin 10 Pin 27 Pin 9 C367P...
  • Page 611 Refer to CAN investigation subtree Investigate CAN A network Complete Were you able to find a Take the actions Is the error code still problem in the CAN A prescribed in the subtree. displayed? network? Contact Dana for further investigation.
  • Page 612 Troubleshooting Complete Remove and replace blown fuse Did fuse F20 blow again Restart the vehicle. F20 from 12V fuse box C14. during test drive? Turn ignition OFF and Disconnect connector C651.B disconnect F20 from 12V fuse from VCU. box C14. Refer to the connector Is there any problem with investigation subtree.
  • Page 613 Is there any evidence of a Defective harness. short circuit within the Replace harness. harness? Replace fuse F20 on 12V fuse box C14. Restart the vehicle. Did fuse F20 blow again Complete during test drive? Contact Dana for further investigation.
  • Page 614 Troubleshooting F0061 - Possible high voltage hazard. Restart prohibited. F0062 - High Voltage System fault. Vehicle cannot start. Error Description Possible Causes Possible Solutions VCU has detected a discontinuity 1) Software HVIL fault. 1) Troubleshoot specific error. in the high voltage interlock loop (HVIL).
  • Page 615 Refer to the specific error F0026, F0139, F0140, F0142, troubleshooting tree. F0143, F0144, F0146? Refer to the Analog HVIL investigation subtree. Could you find any defect in Repair as prescribed the HVIL analog circuit? in the in subtree. Contact Dana for further investigation.
  • Page 616 Troubleshooting F0063 - Vehicle will be disabled soon. Please contact local service. Error Description Possible Causes Possible Solutions VCU has detected a discontinuity 1) Software HVIL fault. 1) Troubleshoot specific error. in the high voltage interlock loop (HVIL). 2) Analog HVIL fault. 2) Troubleshoot specific error.
  • Page 617 Troubleshooting HMI displays or logs Fault code F0063 Apply parking brake and put truck in ready mode. Does the HMI also Refer to the specific error display F0061? troubleshooting tree. Resume operation of the truck, if the error is raised again stop the truck and refer F0061 troubleshooting tree.
  • Page 618 1) Troubleshoot specific error. the high voltage system. This error should be accompanied by the BMS error (F0026) that triggered the shutdown. If error F0092 appears alone, the technician should contact Dana for further investigation. HMI displays or logs Fault code F0092...
  • Page 619 Troubleshooting F0095 - 12V/24V System Voltage is too low. Vehicle may shutdown. Error Description Possible Causes Possible Solutions VCU has detected that the voltage 1) DCDC fault or DCDC no 1) Troubleshoot specific error. on the 12V network is too low. contact.
  • Page 620 Troubleshooting HMI displays or logs Fault code F0095 Has error F0008 or F0144 Refer to the specific error been raised previous to this troubleshooting tree. error being raised? Has a ‘CAN no contact with DCDC’ Refer to the specific error error been raised previous to this troubleshooting tree.
  • Page 621 Troubleshooting Continued from previous page With a multimeter, check for short circuit between the following points: Battery RT020 Ground Connector pin RT020 GND strip1 Low voltage Ground Connector pin RT014 GND strip1 RT013 GND strip1 RT009 GND strip1 RT017 GND strip1 RT011 GND strip1 RT010...
  • Page 622 Troubleshooting Continued from previous page With a multimeter, check for short circuit between the following points: Battery RT020 Battery RT005 Connector pin Connector pin RT020 RT005 -LV short: Resistance measurement is less than 100k- ohms. -Inspect all connectors and wires between the two test points of the harness ends.
  • Page 623 Troubleshooting Continued from previous page With an infrared thermometer check the temperature of the equalizer. Turn OFF the truck, make sure Is the equalizer that the truck is not parked temperature over under the sun and wait 1 hour 100°C? for the equalizer to cool down.
  • Page 624 Troubleshooting With a multimeter, check for continuity between the following points: Voltage equalizer 12V battery Connector pin Connector pin T1:1 RT005 Is the measured Voltage equalizer RT011 voltage in the range Connector pin of 24V? RT034 RT011 RT012 RT013 RT012 RT013 Remove center tap cable and measure - Continuity : Resistance is less than or equal to 2ohms.
  • Page 625 Troubleshooting Replace fuse F1. Disconnect blown fuse F1. Restart the vehicle. Did fuse F1 blow again Disconnect fuse F1. during test drive? With a multimeter, check for short circuit between the following points: RT014 Ground Complete Connector pin RT014 GND strip1 -LV short: Resistance measurement is less than 100k- ohms.
  • Page 626 Troubleshooting Replace fuse F2. Disconnect blown fuse F2. Restart the vehicle. Disconnect fuse F2. Did fuse F2 blow again during test drive? With a multimeter, check for short circuit between the following points: RT013 Ground Connector pin Complete RT013 GND strip1 RT009 Ground Connector pin...
  • Page 627 Troubleshooting F0108 - HV System Fault - Vehicle cannot start Error Description Possible Causes Possible Solutions An attempt was made to start the 1) Cut loop fault. 1) Troubleshoot specific error. vehicle, but the vehicle is prohibited from starting due to a cut loop fault.
  • Page 628 Troubleshooting F0130 - Temperature sensor fault! Outside temp may be inaccurate. Error Description Possible Causes Possible Solutions VCU has detected that the 1) Loss of continuity between 1) Replace LV connector or external temperature sensor is out VCU and temperature sensor harness per Service Manual.
  • Page 629 Troubleshooting HMI displays or logs Fault code F0130 Turn ignition OFF. Disconnect connector C651.B from VCU. Disconnect connector C647. Disconnect connector C676. Disconnect connect C94. Refer to the connector investigation subtree. Is there any Defective connector. problem with the Replace the connector as described in the “Wire connector Harness Connector Identification, Location, and integrity?
  • Page 630 R006. Complete. Does fault still appear after sensor Is the measured resistance Defective R006. replacement with around 10K ohms ? Replace R006 correct part number? Refer to PACCAR for sensor Contact Dana for further investigation and replacement investigation.
  • Page 631 Troubleshooting F0137 - Vehicle Speed cannot be accurately determined Error Description Possible Causes Possible Solutions VCU has determined that its 1) Propulsion or brake fault. 1) Troubleshoot specific error. vehicle speed reading is implausible. 2) Traction inverter internal 2) Replace Traction inverter. failure.
  • Page 632 RPM on the motor speed Replace traction inverter. when driving? Has the gear ratio or tire size Update the vehicle with the been recently changed to non correct parameters corresponding factory standards? to the newly installed equipment. Contact Dana for further investigation.
  • Page 633 Troubleshooting F0145 - Heater failed to turn on Error Description Possible Causes Possible Solutions VCU has detected that the heater 1) Low fluid level in heating 1) Refill fluid. failed to turn on when requested. circuit. 2) Troubleshoot specific error. 2) Heater or heater pump fault.
  • Page 634 Complete display the error ? reservoir. Is the coolant Refill the reservoir. reservoir level low? Does the HMI also display F0143/F0053/F0054/F0055/ Refer to the corresponding F0133/F0134/F0135/F0136/ error troubleshooting tree. ’’Heater No contact’’? Contact Dana for further investigation.
  • Page 635 Troubleshooting F0147 - Please service your cutloop wiring! Error Description Possible Causes Possible Solutions VCU has detected a discontinuity 1) Blown 12V fuse F20. 1) Replace 12V fuse F20. in the cut loop wiring. 2) Loss of continuity due to 2) Replace LV connector or defective LV connector or harness per Service Manual.
  • Page 636 Troubleshooting Connector C676 Circuit73 Connector C651.B...
  • Page 637 Troubleshooting HMI displays or logs Fault code F0147 Does the HMI also Refer to the specific error display F0058? troubleshooting tree. Turn ignition OFF. Inspect fuse F20 on 12V fuse box C14. Is fuse F20 on 12V fuse box C14 blown or intermittent? Disconnect connector C651.B from VCU.
  • Page 638 Pin 10 12V fuse box C14 C40S Terminal Connector Pin 27 - Continuity : Resistance is less than or equal to 2ohms. Contact Dana for further Is there any evidence of Defective harness. investigation. a continuity loss ? Replace harness.
  • Page 639 Troubleshooting Complete Remove and replace blown fuse Did fuse F20 blow again Restart the vehicle. F20 from 12V fuse box C14. during test drive? Turn ignition OFF and Disconnect connector C651.B disconnect F20 from 12V fuse from VCU. box C14. Refer to the connector Is there any problem with investigation subtree.
  • Page 640 Is there any evidence of a Defective harness. short circuit within the Replace harness. harness? Replace fuse F20 on 12V fuse box C14. Restart the vehicle. Did fuse F14 blow again Complete during test drive? Contact Dana for further investigation.
  • Page 641 If the contactors were opened due to a legitimate If error F0148 appears, the technician should contact hazard, the Supervisory Controller will raise error Dana for further investigation. F0051 instead. F0148 will only appear due to a malfunction of the Supervisory Controller.
  • Page 642 If the contactors were opened due to a legitimate If error F0149 appears, the technician should contact hazard, the Supervisory Controller will raise error Dana for further investigation. F0051 instead. F0149 will only appear due to a malfunction of the Supervisory Controller.
  • Page 643 Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed ? network ? subtree. Call DANA for further investigation.
  • Page 644 1) Resolve CAN communication the OnGuard adaptive cruise problem. control (ACC). The OnGuard ACC is not supplied by Dana and is For additional troubleshooting, refer to the OnGuard not within the scope of this guide. documentation. HMI displays or logs...
  • Page 645 1) Resolve CAN communication the OnGuard advance emergency problem. braking system (AEBS). The OnGuard AEBS is not supplied by Dana and is For additional troubleshooting, refer to the OnGuard not within the scope of this guide. documentation. HMI displays or logs...
  • Page 646 Troubleshooting F0156 (Signal Validity Code 1, 2, 31) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller accelerator pedal. needed.
  • Page 647 Refer to CAN investigation subtree Investigate CAN D network. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 648 Troubleshooting F0156 (Signal Validity Code 3, 4, 5, 6, 7, 8, 9, 10, 11, 19, 20, 21, 42, 43, 44, 45, 46, 47, 48, 49) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller...
  • Page 649 Refer to CAN investigation subtree Investigate CAN A network. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN A actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 650 Troubleshooting F0156 (Signal Validity Code 12) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller DCDC. needed. software. 2) DCDC or LV distribution fault. 2) Troubleshoot specific error.
  • Page 651 Investigate CAN A and B networks. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN A or CAN actions prescribed in the displayed? B networks? subtree. Contact Dana for further investigation.
  • Page 652 Troubleshooting F0156 (Signal Validity Code 13, 14, 15, 50) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller DCDC. needed.
  • Page 653 Refer to CAN investigation subtree Investigate CAN D network. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 654 Troubleshooting F0156 (Signal Validity Code 16, 24, 32, 33, 37, 38, 39) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller Traction inverter.
  • Page 655 Refer to CAN investigation subtree Investigate CAN B network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN B actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 656 Troubleshooting F0156 (Signal Validity Code 17, 41) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller hazard light switch. needed.
  • Page 657 Troubleshooting HMI displays or logs Fault code F0156 and Signal validity code 17/41 Does the HMI also Update the supervisory display ‘’Please update controller software following software for CCU/ the procedure provided in the FSVCU’’? maintenance manual. Does the HMI also display ‘’OEM No Refer to PACCAR further investigation.
  • Page 658 Refer to CAN investigation subtree Investigate CAN C network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN C actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 659 Troubleshooting F0156 (Signal Validity Code 18) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid HV contactor controller software update supervisory controller state signal. needed. software. 2) ESS or VCU-HMI fault. 2) Troubleshoot specific error.
  • Page 660 Investigate CAN D and A network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D and A actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 661 Troubleshooting F0156 (Signal Validity Code 22, 26, 27, 28, 34, 35, 36) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller VCU.
  • Page 662 Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 663 Troubleshooting F0156 (Signal Validity Code 23) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid motor torque controller software update supervisory controller request signal from the VCU. needed.
  • Page 664 Refer to CAN investigation subtree Investigate CAN B network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN B actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 665 Troubleshooting F0156 (Signal Validity Code 25, 40) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid signal from the controller software update supervisory controller shift selector. needed. software.
  • Page 666 Refer to CAN investigation subtree Investigate CAN C network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN C actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 667 Troubleshooting F0156 (Signal Validity Code 29, 30) Error Description Possible Causes Possible Solutions Supervisory controller has 1) Charge controller / supervisory 1) Update charge controller / detected an invalid VREFA or controller software update supervisory controller VREFB signal. needed. software. 2) LV distribution fault.
  • Page 668 Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.
  • Page 669 Troubleshooting Override currently active Error Description Possible Causes Possible solutions VCU internal error. 1) Software or calibration error. 1) Contact Dana. ‘Override currently active’ is displayed on the HMI. Contact Dana for further investigation.
  • Page 670 Refer to CAN investigation subtree Investigate CAN D network. Complete Were you able to find a Repair according to the Is the error code still problem in the CAN D actions prescribed in the displayed? network? subtree. Contact Dana for further investigation.

  • Page 671: Powertrain Cooling System

    Troubleshooting Powertrain cooling system The cooling system helps to maintain the proper The radiator and reservoir are not supplied by Dana operating temperature for the equipment connected and are outside the scope of this troubleshooting to the cooling circuit. It consists of a cooling loop, guide.
  • Page 672 Troubleshooting F0059 - Powertrain cooling system fault Error Description Possible Causes Possible Solutions Powertrain Coolant Pump has 1) DCDC fault. 1) Troubleshoot specific error. reported a problem resulting in reduced performance. 2) Blown 24V fuse F6. 2) Replace 24V fuse F6. 3) Blown 24V fuse F16.
  • Page 673 Troubleshooting HMI displays or logs Fault code F0059 Check the HMI for other faults. Does the HMI also display “F0008 - 12V/ Refer to error F0008 24V Charging System troubleshooting tree. Fault”? Wait for 10 minutes before Inspect fuse F6 in the 24V fuse Turn ignition OFF.
  • Page 674 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace harness. Refer to the cooling Investigation subtree. Was any root cause found Complete in the cooling circuit? Contact DANA for further investigation.
  • Page 675 Is there any evidence of a short Defective harness. circuit within the Replace harness. harness ? Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again Complete Restart the vehicle. during test drive? Contact Dana for further investigation.
  • Page 676 Is there any Defective harness. evidence of a short circuit Replace harness. within the harness ? Replace fuse F16 on 24V fuse box Did fuse F16 blow again C20. Complete during test drive? Restart the vehicle. Contact Dana for further investigation.
  • Page 677 Troubleshooting F0060 - Powertrain cooling system fault Error Description Possible Causes Possible Solutions Powertrain Coolant Pump has 1) DCDC fault. 1) Troubleshoot specific error. reported a problem resulting in failure of the pump. 2) Blown 24V fuse F6. 2) Replace 24V fuse F6. 3) Blown 24V fuse F16.
  • Page 678 Troubleshooting HMI displays or logs Fault code F0060 Check the HMI for other faults. Does the HMI also display “F0008 - 12V/ Refer to error F0008 24V Charging System troubleshooting tree. Fault”? Wait for 10 minutes before Inspect fuse F6 in the 24V fuse Turn ignition OFF.
  • Page 679 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: Coolant Pump C81 24V fuse box C20...
  • Page 680 Is the coolant level low? leaks. Is there any leak in the Repair the leak and refill cooling circuit? coolant. Refer to the CAN Investigation subtree. Refill coolant. Investigate CAN D network. Is the error still raised? Complete Contact Dana for further investigation.
  • Page 681 Is there any evidence of a short Defective harness. circuit within the Replace harness. harness ? Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again Complete Restart the vehicle. during test drive? Contact Dana for further investigation.
  • Page 682 Is there any Defective harness. evidence of a short circuit Replace harness. within the harness ? Replace fuse F16 on 24V fuse box Did fuse F16 blow again C20. Complete during test drive? Restart the vehicle. Contact Dana for further investigation.
  • Page 683 Troubleshooting F0109 - Powertrain Cooling System Sensor Fault Error Description Possible Causes Possible Solutions Powertrain Coolant Pump has 1) Short circuit in coolant level 1) Replace LV connector or detected that its coolant level sensor harness. harness per Service Manual. sensor is shorted.
  • Page 684 Troubleshooting F0110 - Powertrain Cooling System Sensor Fault Error Description Possible Causes Possible Solutions Powertrain Coolant Pump has 1) Loss of continuity between 1) Replace LV connector or detected a loss of continuity with Powertrain Coolant Pump and harness per Service Manual. its coolant level sensor.
  • Page 685 Troubleshooting Powertrain cooling pump no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from the Powertrain problem. Coolant Pump within a specified 2) Blown 24V fuse F6. time interval.
  • Page 686 Troubleshooting HMI displays “Powertrain cooling pump No contact.” Check the HMI for other faults. Does the HMI also display “F0008 - 12V/ Refer to error F0008 troubleshooting tree. 24V Charging System Fault”? Wait for 10 minutes before Inspect fuse F6 in the 24V fuse Turn ignition OFF.
  • Page 687 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. continuity loss? Replace or repair harness. Refer to the CAN Investigation subtree. Is the error still raised? Complete Investigate CAN D network. Contact Dana for further investigation.
  • Page 688 Is there any evidence of a short Defective harness. circuit within the Replace harness. harness ? Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again Complete Restart the vehicle. during test drive? Contact Dana for further investigation.
  • Page 689 Is there any Defective harness. evidence of a short circuit Replace harness. within the harness ? Replace fuse F16 on 24V fuse box Did fuse F16 blow again C20. Complete during test drive? Restart the vehicle. Contact Dana for further investigation.

  • Page 690: Telemetry System

    Troubleshooting Telemetry System The telemetry system collects and transmits operational data from the various vehicle systems to Modem remote servers where they can be accessed by The modem manages wireless communications operators for monitoring purposes. between the telemetry module and the remote server.
  • Page 691 Troubleshooting Telemetry No Contact OR Fleet owner is receiving empty telemetry data files Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from the telemetry problem. module within a specified time 2) LV distribution fault.
  • Page 692 Troubleshooting Connector C661 Connector C416 Connector C699P (pin) Connector C621 Connector C699S (socket)
  • Page 693 Troubleshooting HMI displays “Telemetry No Contact” Fleet owner is receiving empty telemetry data files Refer to CAN investigation subtree Investigate CAN B network Complete Were you able to find a Take the actions Is the error code still problem in the CAN B prescribed in the subtree.
  • Page 694 Troubleshooting Continued from previous page Disconnect connector C12 from MPDM. Remove fuse F14 from 12V fuse box C14 in order to take continuity measures from inside the fuse box. Disconnect connector C416 from FleetManagementKit. Disconnect connector C699. Refer to the connector investigation subtree.
  • Page 695 Troubleshooting Continued from previous page Is there any evidence of Defective harness. a continuity loss ? Replace harness. Replace timer relay 2. Turn ignition ON. Does the HMI still display ‘’Telemetry No Complete Contact’’? Contact Dana for further investigation.
  • Page 696 Troubleshooting Disconnect blown fuse F14 from 12V fuse box C14. Replace fuse F14 on 12V fuse box C14. Restart the vehicle. Did fuse F14 blow again Complete during a test drive? Turn ignition OFF and disconnect F14 from 12V fuse box C14.
  • Page 697 Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F14 on 12V fuse box C14. Restart the vehicle. Did fuse F14 blow again Complete during a test drive? Contact Dana for further investigation.
  • Page 698 Troubleshooting Disconnect blown fuse F14 from MPDM. Replace fuse F14 in MPDM. Restart the vehicle. Did fuse F14 blow again Complete during a test drive? Turn ignition OFF and disconnect F14 from MPDM. Disconnect connector C12 from MPDM. Disconnect connector C416 from FleetManagementKit.
  • Page 699 Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F14 on MPDM. Restart the vehicle. Did fuse F14 blow again Complete during a test drive? Contact Dana for further investigation.

  • Page 700: Epto System

    Troubleshooting ePTO System The electric power take-off (ePTO) system provides an electrical power output which can be used to operate aftermarket onboard accessories.
  • Page 701 Troubleshooting F0015 - PTO unavailable Error Description Possible Causes Possible Solutions ePTO is offline. 1) ESS, DCDC, or LV distribution 1) Troubleshoot specific error. fault. 2) Replace 12V fuse F11. 2) Blown 12V fuse F11. 3) Replace LV connector or 3) Loss of continuity due to harness per Service Manual.
  • Page 702 Troubleshooting Connector C722 Connector C101 Connector C713...
  • Page 703 Troubleshooting HMI displays or logs Fault code F0015 Does the HMI also Refer to the specific error display F0026, F0095 or troubleshooting tree. F0008? Inspect fuse F11 on 12V fuse box C14. Is fuse F11 on 12V fuse box C14 blown or intermittent? Disconnect connector C6 from ePTO.
  • Page 704 Troubleshooting Continued from previous page Is there any Defective connector. problem with the Replace the connector as described in the “Wire connector Harness Connector Identification, Location, and integrity? Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: 12V fuse box C14 C15S...
  • Page 705 Pin 1 Pin 2 RT045 RT044 Connector pin Connector pin RT045 RT044 - Continuity : Resistance is less than or equal to 2ohms. Is there any Defective harness. evidence of a Replace harness. continuity loss ? Contact Dana for further investigation.
  • Page 706 -Inspect all connectors and wires between the two test points of the harness ends. Replace fuse F11 on 12V fuse box C14. Restart the vehicle. Contact Dana for further Did fuse F11 blow again investigation. during a test drive? Complete...
  • Page 707 Troubleshooting F0139 - Potential High Voltage Hazard! ePTO HVIL Fault Error Description Possible Causes Possible Solutions ePTO has reported a discontinuity 1) HV connector unplugged. 1) Plug in HV connector. in the HVIL. 2) Defective HV connector or 2) Replace HV harness. harness.
  • Page 708 Could you find any defect in Repair as prescribed in the HVIL analog circuit? the in subtree. WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Contact Dana for further investigation. Continued on next page...
  • Page 709 Troubleshooting Continued from previous page Disconnect connector C722 from the ePTO. Refer to connector investigation subtree. Is there any problem with Defective connector. the connector integrity? Replace harness. With a multimeter, check for continuity between the following points: ePTO C722P ePTO C722P Connector pin Connector pin...

  • Page 710: Epto No Contact

    Troubleshooting ePTO no contact Error Description Possible Causes Possible Solutions VCU has not received any CAN 1) CAN communication problem. 1) Resolve CAN communication message from the ePTO within a problem. specified time interval. 2) LV distribution fault. 2) Troubleshoot specific error. 3) Blown 12V fuse F11.
  • Page 711 Troubleshooting Connector C101...
  • Page 712 Troubleshooting HMI displays “ePTO No contact.” Refer to CAN investigation subtree Investigate CAN D network Complete Were you able to find a Take the actions Is the error code still problem in the CAN D prescribed in the subtree. displayed? network? Does the HMI also Refer to error F0095...
  • Page 713 C15S C101 ground Connector pin Connector pin Pin 9 Pin 2 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence of Defective harness. a continuity loss ? Replace harness. Contact Dana for further investigation.
  • Page 714 -Inspect all connectors and wires between the two test points of the harness ends. Replace fuse F11 on 12V fuse box C14. Restart the vehicle. Contact Dana for further Did fuse F11 blow again investigation. during a test drive? Complete...

  • Page 715: Troubleshooting Subtrees

    Troubleshooting Troubleshooting Subtrees This section contains subtrees to assist the troubleshooting of a specific error message. When technician in troubleshooting general problems the actions prescribed in the subtree have been which may cause a variety of different specific error completed, the technician should return to the messages to appear.

  • Page 716: Analog Hvil Investigation

    Troubleshooting Analog HVIL Investigation This subtree is used to troubleshoot errors in the analog high voltage interlock loop (HVIL) when requested during troubleshooting of a specific error message. When the analog HVIL investigation subtree is completed, the technician should return to the original troubleshooting tree.
  • Page 717 Troubleshooting Connector C91 Connector C22 Connector C202 Connector C40 Connector C300 Connector C73...
  • Page 718 Troubleshooting Connector C367S (socket) Connector C367P (pin) Connector C676 Circuit73 Connector C651.B...
  • Page 719 Troubleshooting This troubleshooting tree is used when there is a problem with the analog HVIL. Inspect fuse F3 on 12V fuse WARNING: Electrical hazard. box C14. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Is fuse F3 blown or intermittent? Disconnect connector C5...
  • Page 720 Troubleshooting Continued from previous page Is there any evidence Contact Dana for further of a continuity loss? investigation. Perform a wiggle test on all connectors connected to the HV junction box: - Move the connector side to side gently and...
  • Page 721 Troubleshooting Complete Replace fuse F3 on 12V fuse box Disconnect blown fuse F3 from Did fuse F3 blow again C14. 12V fuse box C14. during test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect connector C5 from the disconnect F3 from 12V fuse box investigation subtree.
  • Page 722 Troubleshooting Continued from previous page Is there any evidence of a Defective harness. short circuit on one of these Replace defective segment. segments? With a multimeter, perform a continuity test between: - Connector C300P pin 1 and casing and ground. - Connector C300P pin 6 and casing and ground.
  • Page 723 Troubleshooting Disconnect connector C3 from MCU. Disconnect connector C22 from OBC. Disconnect connector C73 from HTR. Disconnect connector C202 from Air break compressor. Disconnect connector C40. Disconnect connector C367. Disconnect C15. Disconnect connector C91. Disconnect connector 651.B from VCU. Refer to the connector investigation subtree.
  • Page 724 Pin 9 C676P C651.B VCU Connector pin Connector pin Pin 9 Pin 28 - Continuity : Resistance is less than or equal to 2ohms. Is there any evidence Defective harness. of a continuity loss? Replace harness. Contact Dana for further investigation.

  • Page 725: Can Investigation

    Troubleshooting CAN Investigation This subtree is used to troubleshoot errors in the CAN network when requested during troubleshooting The specific connectors and pins to be accessed of a specific error message. When the CAN during this troubleshooting procedure depend on investigation subtree is completed, the technician which CAN network is being investigated.
  • Page 726 Troubleshooting CAN A Devices and Connectors CAN connector CAN High pin CAN Low pin Diagnostics C410 C651.A A/C compressor C203 C202 PNOVO+ Termination resistor 1 C53.A Termination resistor 2 C649.A Connector C44 Connector C53.A Connector C53 Connector C71...
  • Page 727 Troubleshooting Connector C202 Connector C410 Connector C203 Connector C649.A Connector C651.A...
  • Page 728 Troubleshooting CAN B Devices and Connectors CAN connector CAN High pin CAN Low pin Diagnostics C410 C651.A C650.A TELEMETRY C416 Traction inverter CHILLER PNOVO+ Termination resistor 1 C53.B Termination resistor 2 C649.B Connector C45 Connector C3 Connector C53 Connector C22...
  • Page 729 Troubleshooting Connector C53.B Connector C649.B Connector C410 Connector C650.A Connector C416...
  • Page 730 Troubleshooting Connector C651.A...
  • Page 731 OEM_RADAR OEM_RADAR PNOVO+ Termination resistor 1 C53.C Termination resistor 2 C649.C Note: Connectors D358, D366, D376, P101, and OEM_RADAR are not supplied by Dana. Consult the appropriate reference document for details about these connectors. Connector C53 Connector C10 Connector C53.C...
  • Page 732 Troubleshooting Connector C72 Connector C410 Connector C82 Connector C649.C Connector C89 Connector C650.A...
  • Page 733 Troubleshooting Connector C651.A...
  • Page 734 Troubleshooting CAN D Devices and Connectors CAN connector CAN High pin CAN Low pin Diagnostics C410 C651.B C650.A CLD_PMP EPTO1 EHPS_INV EHPS_INV DCDC PNOVO+ Termination resistor 1 C53.D Termination resistor 2 C649.D Connector C53 Connector C6 Connector C53.D Connector C34...
  • Page 735 Troubleshooting Connector C80 Connector C649.D Connector C84 Connector C650.A Connector C410...
  • Page 736 Troubleshooting Circuit73 Connector C651.B...
  • Page 737 Troubleshooting CAN E Devices and Connectors CAN connector CAN High pin CAN Low pin Diagnostics C410 C651.B C650.A Termination resistor 1 C446 Termination resistor 2 C649.E Connector C649.E Connector C410 Connector C446 Connector C650.A...
  • Page 738 Troubleshooting Circuit73 Connector C651.B...
  • Page 739 CAN network. Cycle the ignition and check fault codes after each to determine when the fault is no longer present. Could you find a system/device causing the CAN network fault? Contact Dana for further investigation.
  • Page 740 Troubleshooting A termination resistor may be defective, or not connected to the network. Is resistance Disconnect termination resistor 1. Measure across the resistor resistance between CAN_H and CAN_L on the 108 - 132 ohms? resistor pins and on the harness pins . Replace termination resistor 1 Is resistance...
  • Page 741 Troubleshooting There are too many termination resistors on the network. Is resistance across Disconnect termination resistor 1. the resistor pins Measure resistance between CAN_H 108-132 ohms? and CAN_L on the resistor pins and on the harness pins. Replace termination resistor 1 Is resistance across Replace the harness pins...
  • Page 742 Continued from previous page Disconnect modules one by one and measure the resistance between CAN_H and CAN_L on the harness side to identify any parasitic resistance. Is there a parasitic Defective harness. resistance found? Replace harness. Contact Dana for further investigation...

  • Page 743: Connector Investigation

    Troubleshooting Connector Investigation This subtree is used to troubleshoot problems with technician should return to the original electrical connectors when requested during troubleshooting tree. troubleshooting of a specific error message. When the connector investigation subtree is completed, the...
  • Page 744 Troubleshooting Connector integrity Inspection Fully plug in the connector, Are primary and ensuring that primary and secondary locks fully secondary locks are locked locked? correctly. Is the initial code you were troubleshooting still being raised? Complete. Are any of the connector pins in the suspect device connector bent, broken, or...
  • Page 745 Troubleshooting Is there evidence of a foreign material in one of the connectors, a Remove any foreign material from product pin surface damaged, evidence of the connectors. dirt or too much protective grease? (Inspect both male and female connectors.) Clean connector pins (male, female or both) with isopropyl alcohol using a brush.

  • Page 746: Cooling System Investigation

    Troubleshooting Cooling System Investigation This subtree is used to troubleshoot problems with completed, the technician should return to the the cooling system when requested during original troubleshooting tree. troubleshooting of a specific error message. When the cooling system investigation subtree is Cooling investigation Does the HMI display error F0105...
  • Page 747 Troubleshooting Continued from previous page Is the coolant level low? Turn ignition OFF. While the pump is off, check the coolant level in the reservoir. Check the cooling circuit for Is the coolant level low? leaks. Inspect each hose in the cooling Repair the leak and refill Is there any leak in the circuit.
  • Page 748 Troubleshooting Heating Circuit Investigation This subtree is used to troubleshoot problems with the heating circuit when requested during troubleshooting of a specific error message. When the heating circuit investigation subtree is completed, the technician should return to the original troubleshooting tree. Connector C74 Circuit73 Connector C651.B...
  • Page 749 Troubleshooting Heating circuit investigation If the heater was used recently, wait for components to cool down. Is the fluid in the Drain and flush heating circuit. heating circuit the Refill with correct fluid. correct specification? Check the fluid level in the heating circuit reservoir.
  • Page 750 Troubleshooting Continued from previous page Connect, repair, or replace the Is any hose kinked, hose. pinched, or loose? Refill fluid if necessary. Use the service interface to activate the heater pump. Does the heater pump run when requested? Does fluid flow out of the reservoir when the Complete pump is running?
  • Page 751 Is the problem Complete resolved? Disconnect the heating circuit one section at a time and check for obstructions. Is the heating circuit Clear obstruction, reconnect obstructed? hoses, and refill fluid as needed. Contact DANA for further investigation.
  • Page 752 Troubleshooting WARNING: Electrical hazard. Follow Safety Warnings and High Voltage Shutdown Procedures defined in the Service Manual and Diagnostic Guide. Inspect fuse F15 in the 12V fuse box C14. Is fuse F15 blown or intermittent? Disconnect connector C74 from heater pump. Disconnect connector C651.B from VCU.
  • Page 753 Troubleshooting Continued from previous page Defective connector. Is there any problem with Replace the connector as described in the “Wire the connector integrity? Harness Connector Identification, Location, and Service Chart” in the Service Manual With a multimeter, check for continuity between the following points: 12V fuse box C14 Connector pin...
  • Page 754 Troubleshooting Complete Replace fuse F15 on 12V fuse Disconnect blown fuse F15 from Did fuse F15 blow again box C14. 12V fuse box C14. during a test drive? Restart the vehicle. Turn ignition OFF and Refer to the connector Disconnect connector C74 from disconnect F15 from 12V fuse investigation subtree.
  • Page 755 Troubleshooting Continued from previous page Is there any evidence Defective harness. of a short circuit Replace harness. within the harness? Replace fuse F15 on 12V fuse box C14. Restart the vehicle. Did fuse F15 blow again Complete during a test drive? Defective heater pump.
  • Page 756 Troubleshooting Relay Investigation This subtree is used to troubleshoot problems with relays when requested during troubleshooting of a The relays on the vehicle and their pins are listed in specific error message. When the relay investigation the table below. subtree is completed, the technician should return to the original troubleshooting tree.
  • Page 757 Troubleshooting Relay investigation subtree Disconnect the concerned relay. Refer to the subtree description to find out the pins to investigate. With a multimeter measure the resistance between the following pins of the relay : Relay Relay Connector Connector Pin B Pin A The multimeter should read a resistance around 0 ohms between these two pins.
  • Page 758 Troubleshooting Continued from previous page Is the relay correctly closing and opening when Defective relay. a 12V voltage is applied Replace relay. and removed ? With a multimeter measure the resistance between the following pins of the relay : Relay Relay Connector Connector...

  • Page 759: Appendix 1: Terminology

    Troubleshooting Appendix 1: Terminology The names of systems and devices used in this guide may differ from those used in supplier documentation, electrical schematics, or vehicle software. This table provides the electrical schematic abbreviation and any alternate names for each device. This guide Electrical schematics Software or supplier documentation...

  • Page 760: Hvac System

    Troubleshooting This guide Electrical schematics Software or supplier documentation HVAC system A/C compressor HVAC CAN/LIN CN_LN CAN to LIN converter Radiator Fan 01 CND_FAN_1 Radiator Fan 01 Radiator Fan 02 CND_FAN_2 Radiator Fan 02 Cabin Heater Cabin Heater Heater pump HT_PMP HVAC water pump VCU-HMI system...
  • Page 761 For spec’ing or service assistance, call 1-877-777-5360 or visit our website at www.Dana.com All applications must be approved by the Application Engineering Department. Specifications and/or design are subject to change without notice or obligation. Printed in USA...

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