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PACCAR® Electrified Chassis Troubleshooting Guide

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0% found this document useful (0 votes)

88 views761 pages

PACCAR® Electrified Chassis Troubleshooting Guide

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soicanhavefriends

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Download as PDF, TXT or read online on Scribd

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PACCAR® Electrified Chassis

Troubleshooting Guide

ECTS-0300
October 2022
Models 220ev, K270e & K370e
DOC00015340
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. Safety alerts are highlighted by safety alert symbols and signal words such as "Warning", "Caution",
or "Note.” Do not ignore any of these alerts.

Warning The safety message following this symbol and word

provides a warning against operating procedures that could
cause serious injury or even death. Failure to follow these
warnings could also cause equipment or property damage.
The alert will identify a hazard, how to avoid it, and the
probable consequence of not avoiding the hazard.

Caution The safety alert following this symbol and word provides a
caution against operating procedures that could cause
equipment or property damage. The alert will identify a
hazard, how to avoid it, and the probable consequence if
ignored.

Note
The alert following this symbol and word provides important
information that is not safety related but should be followed.
The alert will highlight things that may not be obvious and is
useful to your efficient operation of the vehicle.

2
Safety Warnings

Warnings and Safety Regulations Warning: The high voltage cables must be
shielded and colored orange.
Warning: The following warning and safety
regulations must be strictly observed for The high voltage and level of current
your safety, for bystanders’ safety, and to delivered by these systems can be lethal.
prevent vehicle damage.
Failure to shield the high-voltage cables will
General Warning result in non-compliance with EMI
regulatory requirements.
Warning: This vehicle generates high
voltage that can cause an electric discharge Warning: The systems use differential
resulting in severe injury or death. mode capacitors between the positive high-
voltage DC bus (+) and the negative high-
Training Requirements voltage DC bus (-) and common mode
capacitors between the high-voltage DC
Warning: All troubleshooting must be bus and the chassis. Even when the
performed by qualified technicians trained product is disconnected from the high-
in high voltage safety. voltage source, these capacitors can hold a
voltage high enough to cause an electric
Technicians must be fully aware of the discharge or death.
types of hazards involved in working with
electrical circuitry and familiar with standard Electrical Equipment
practices for preventing accidents.
Warning: Make sure the high voltage (HV)
The dealership is responsible for ensuring and low voltage (LV) electrical supplies are
that technicians are properly trained. shut off when working with electrical
components or wiring.
Warning: Vehicle systems must be
installed by qualified and authorized Warning: After disconnecting the electrical
personnel in accordance with applicable supply, wait 5 minutes before proceeding to
vehicle standards and industry practices. allow time for capacitors to discharge.

Personal Protective Equipment HV Junction Box

Warning: Always use appropriate personal Warning: Do not open the HV junction box
protective equipment (PPE) when working unless specifically instructed by this guide
with the vehicle systems, even when the or by Dana.
system is disconnected from a high voltage
source. Warning: Before performing any
troubleshooting of the HV junction box,
General High Voltage Warnings make sure to follow the instructions of the
Operation and Maintenance Manual to
Warning: Improper handling of high voltage safely operate on this system. Failure to do
(HV) equipment can cause serious injury or so may result in serious injury or death.
death.
Pneumatic Equipment
Warning: Do not perform any
troubleshooting of HV equipment unless Warning: Pneumatic equipment can cause
specifically instructed by this guide or by serious injury. Make sure the system is
Dana. depressurized before performing any
maintenance on the air brake system or
Warning: Wear appropriate personal other pneumatic components.
protective equipment (PPE) when working
with high voltage (HV) equipment.

3
Safety Warnings

Modifications of the Vehicle Fire Instructions:

Modifying the vehicle could make it unsafe. Some During a fire, certain plastic seals can produce
modifications could affect the vehicle's electrical gases which with water form a corrosive acid. Do
system, stability, or other important functions. 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. Note: Do not attempt to put out a battery
pack fire with the provided fire extinguisher.
Warning: Connecting to an unapproved
CAN (Controller Area Network) bus may
2. Create a safety perimeter of at least 6 feet
trigger CAN fault codes. The manufacturer
around the vehicle.
will not warrant failures or damage caused
to the CAN bus components or vehicle
3. If it is possible, take the keys out of the ignition
when the failure or damage due to improper
and turn the 12V Disconnect to the “OFF” position.
connections to the CAN bus or improper
messages.
Oils and Lubricants
Cooling System Filler Cap Various kinds of oil and other lubricants used on the
vehicle may constitute a health hazard if they
Warning: Do not remove the radiator fill
contact the skin. This also applies to electric
cap while the powertrain is hot. Scalding
powertrain coolant, refrigerant in air conditioning
steam and fluid under pressure may
systems, and battery acid. Do not contact vehicle
escape. You could be badly burned. Failure
liquids without the appropriate personal protective
to comply may result in death or personal
equipment.
injury.
Caution: The refrigerant lube used on this
Coolant
truck is different from the typical refrigerant
Caution: To prevent corrosion problems in lube used for PACCAR vehicles. Failure to
cooling systems, the following use the correct refrigerant lube could result
recommended best practices should be in isolation failures.
observed:
• The coolant should consist of 60% Maintenance Activities
ethylene glycol, 40% de-ionized water
When carrying out maintenance work under the
(not distilled water).
cab, make sure the cab is fully tilted and locked to
• A minimum of 50% ethylene glycol is prevent it from falling back accidentally.
required. Following a collision, only tilt the cab in an
• The ethylene glycol must contain some emergency. The tilting mechanism may be
type of active corrosion inhibitor. damaged, and a high voltage hazard might exist.
• Do not mix different types of coolant. (The end stop may no longer be on the lifting
cylinder.)
Fire Extinguisher
Warning: Always support the vehicle with
Ensure that an approved fire extinguisher is within appropriate safety stands if it is necessary
the driver's reach and easily accessible for first to work underneath the vehicle. A jack is
responders. Routinely check the fire extinguisher not adequate for this purpose.
according to its manufacturer’s instructions. If the
fire extinguisher has been used, it must be replaced
with a new fire extinguisher or refilled according to
the manufacturer’s instructions before the truck can
be returned to service.

4
Safety Warnings

Environment or fitting electrical or electronic components, always

verify that they are suitable for the system voltage.
Pollution is a serious threat to the environment. To
keep pollution to a minimum, follow the below rules: LV Batteries

• Do not dump used oil, lubricants, hydraulic fluid, Warning: Always disconnect the battery
or coolants in drains, in sewers, in landfills or on negative (ground) lead before carrying out
the ground. This is illegal. All used fluids must repairs or service on the electrical system.
be stored separately.
• Service the vehicle regularly according to the Warning: Before attempting any work on
instructions and recommendations in the the batteries or electrical system, remove all
service manual. If component service intervals jewelry. If metal jewelry or other metal
are not provided in the service manual, check contacts with electrical circuits, a short
the truck manufacturer’s operator’s manual. circuit may occur, causing personal injury
and causing electrical system failure and
High Voltage (HV) System damage.

Warning: Do not disassemble, remove, or Jump-Starting Introduction

replace any high voltage component, cable,
or connector unless specifically instructed Jump-starting a vehicle is not a recommended
by this guide. All high voltage cables are practice due to the various LV battery installations
colored orange for easy identification. and electrical options. However, if your LV battery is
discharged (dead), you may be able to start it by
Warning: The high voltage batteries are not using energy from a good LV battery in another
serviceable and should NEVER be opened. vehicle. This is termed jump-starting. Be sure to
Only the MSDs and HV cable connections follow the precautions and instructions below.
should be accessed according to repair and
safety procedures. LV Charging Reminders

Note: If a collision occurs, remove the keys • Use protective eyewear.

from the ignition (if they are safely • Keep all batteries away from children.
accessible) and do not touch any high • Never reverse LV battery poles.
voltage cables, connectors, or components. • Never attempt to place the vehicle in motion
with LV batteries disconnected.
Note: In the unlikely event of a fire, • Keep the LV battery clean and dry.
immediately contact your local fire • Look for any signs of damage. Replace
emergency responders. damaged 12V batteries according to the battery
manufacturer’s guidelines.
Welding • Do not coat LV battery terminals with an
improper grease. Use petroleum jelly or
Caution: Frame rails are heat-treated and commercially available, noncorrosive,
should not be welded. Electrical nonconducting terminal coatings.
components nearby welding could also be • Refer to the LV system charging and jump
damaged. Dana’s warranty does not cover starting instructions for proper procedure.
damage to components caused by any type • It is preferred that 24V be provided across the 2
of welding. LV batteries. If only 12V source is available,
the connection must be across the second LV
Warning: Prior to performing any battery so that the equalizer can distribute
maintenance on the electric vehicle, always power to the first LV battery.
perform the HV voltage shutdown
procedure. Warning: Thaw frozen LV batteries at room
temperature before charging them. Remove
Low Voltage (LV) System all the filler caps before charging.

The cab system of this vehicle operates on 24V

while other areas operate on 12V. When replacing

5
Safety Warnings

Warning: Charger cables must be Caution: Do not modify or improperly repair

connected positive to positive (+ to +) and the vehicle’s electrical system or electric
negative to negative (- to -). If connected powertrain. All electrical repairs should be
improperly, LV batteries could explode. performed by an authorized dealer.
Failure to comply may result in personal Improper repair or modifications will void
injury, death, equipment, or property the warranty and/or cause serious damage
damage. to your vehicle.

Warning: Always ensure the LV battery

charger is OFF before connecting or Additional Information
disconnecting the cable clamps. To reduce
the danger of explosions and resulting Note: Review the warranty policy before
death or personal injury, do not connect or performing any maintenance procedures.
disconnect charger cables while the charger An extended warranty may be voided if
is operating. unauthorized maintenance is performed
during this period.
Warning: Never use a fast charger as a
booster to start the system. This can Note: The description and specifications
seriously damage sensitive electronic contained in the service publication are
components such as relays, radio, as well current at the time of printing.
as the LV battery charger. Fast charging a
LV battery is dangerous and should only be Note: Dana reserves the right to
attempted by a competent mechanic with discontinue or modify its models and/or
the proper equipment. procedures and to change specifications at
any time without notice.
Warning: LV batteries contain acid that can
burn and gasses that can explode. Ignoring Note: Always use genuine Dana
safety procedures may result in death, replacement parts.
personal injury, equipment, or property
damage.
Note: Every effort has been made to
ensure the accuracy of all information in this
Warning: Never remove or tamper with LV
guide. However, Dana Commercial Vehicle
battery caps. Ignoring this could allow LV
Systems Division makes no express or
battery acid to contact the eyes, skin,
implied warranty or representation based on
fabrics, or painted surfaces. Failure to
the enclosed information.
comply may result in death, personal injury,
equipment, or property damage. Be careful
Any errors or omissions may be reported to:
that metal tools (or any metal in contact with
the positive terminal) do not contact the
Dana Commercial Vehicle Systems
positive battery terminal and any other
3939 Technology Drive
metal on the vehicle at the same time.
Maumee, OH 43537
Remove metal jewelry and avoid leaning
over the LV battery.

Caution: Using higher voltage booster for

the LV batteries will cause expensive
damage to sensitive electronic components
such as relays, sensors, and control units.
Always charge the LV batteries at the
proper voltage. Failure to comply may result
in equipment damage.

6
Table of Contents

Safety Alerts and Warnings ................... 2 How to Use This Guide .................................17
Safety Alerts .................................................... 2 ESS ...............................................................19
Warnings and Safety Regulations ................... 3 Charging System .........................................161

Error Code Index..................................... 8 Propulsion System ......................................270

Brake System ..............................................325
General Information.............................. 12
DCDC System .............................................417
PACCAR vehicle ........................................... 12
Low Voltage Distribution System.................465
Key Features ................................................. 12
Power Steering System ...............................480
Vehicle System Overview ............................. 13
HVAC System..............................................522
Diagnostics ........................................... 14
VCU-HMI System ........................................602
Fault Codes ................................................... 14
Powertrain cooling system ..........................671
Fault Reasons ............................................... 14
Telemetry System........................................690
Fault Log ....................................................... 14
ePTO System ..............................................700
Operational Data ........................................... 14
Troubleshooting Subtrees ...........................715
Multimeter ..................................................... 15
Appendix 1: Terminology ................... 759
Troubleshooting Tips..................................... 16
Troubleshooting ................................... 17

7
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 ................................... 716 Fault Reason 0x4ff8e4 .................................... 381
BMS no contact ................................................... 150 Fault Reason 0x74f7ec, 0x75f7ed .................. 386
Cabin Heater no contact ...................................... 596 Fault Reason 0xa1f8e2 ................................... 387
CAN investigation ................................................ 725 Fault Reason 0xa2f8ec ................................... 390
Charge controller no contact ............................... 262 Fault Reason 0xa5f8e0 ................................... 391
Connector investigation ....................................... 743 Fault Reason 0xa6f8e0 ................................... 392
Cooling system investigation ............................... 746 Fault Reason 0xd0f9e4 ................................... 393
DCDC no contact ................................................. 457 Fault Reason 0xd3f9e4 ................................... 396
ePTO no contact .................................................. 710 Fault Reason 0xd4f9e2 ................................... 399
F0000 Fault Reason 0xe2f9e4 ................................... 400
Fault Reason 0x02faff ...................................... 326 Fault Reason 0xe3f9e4 ................................... 401
Fault Reason 0x05faff ...................................... 327 Fault Reason 0xe4f9e4 ................................... 402
Fault Reason 0x07faff ...................................... 328 F0003 .................................................................. 162
Fault Reason 0x08faff ...................................... 329 F0004 .................................................................. 163
Fault Reason 0x0afae0, 0x0afaf0 .................... 330 F0005, F0006, F0007
Fault Reason 0x233302 ................................... 331 Charge end reason 1 ...................................... 164
Fault Reason 0x233608, 0x233708, 0x233808 Charge end reason 2 ...................................... 166
...................................................................... 333 Charge end reason 3 ...................................... 168
Fault Reason 0x233B0A .................................. 334 Charge end reason 4 ...................................... 170
Fault Reason 0x234101 ................................... 335 Charge end reason 5 ...................................... 172
Fault Reason 0x234606, 0x234705 ................. 336 Charge end reason 6 ...................................... 174
Fault Reason 0xa1f8ec .................................... 337 Charge end reason 7 ...................................... 175
Fault Reason 0xa3f8ec .................................... 338 Charge end reason 8 ...................................... 177
Fault Reason 0xa4f8f2 ..................................... 339 Charge end reason 9 ...................................... 179
Fault Reason 0xa4f8ff ...................................... 341 Charge end reason 10 .................................... 181
Fault Reason 0xa5f8f0 ..................................... 342 Charge end reason 11 .................................... 183
Fault Reason 0xa6f8f0 ..................................... 344 Charge end reason 12 .................................... 185
Fault Reason 0xa7f8ec .................................... 346 Charge end reason 13 .................................... 187
Fault Reason 0xcef9f0, 0xd1f9ef ..................... 348 Charge end reason 14 .................................... 189
Fault Reason 0xd5f9f0, 0xd6f9e1 .................... 350 Charge end reason 15 .................................... 191
Fault Reason 0xd9f9e2 .................................... 352 Charge end reason 16 .................................... 194
Fault Reason 0xdaf9e2 .................................... 354 Charge end reason 17 .................................... 196
Fault Reason 0xdcf9f0, 0xddf9f0, 0xdef9f0 ..... 348 Charge end reason 18 .................................... 199
Fault Reason 0xfef9ff ....................................... 356 Charge end reason 19 .................................... 202
F0001 ................................................................... 357 Charge end reason 20 .................................... 205
F0002 Charge end reason 21 .................................... 208
Fault Reason 0x00faff ...................................... 358 Charge end reason 22 .................................... 211
Fault Reason 0x01faff ...................................... 359 Charge end reason 23 .................................... 213
Fault Reason 0x03faff ...................................... 360 Charge end reason 24 .................................... 215
Fault Reason 0x04f9e2 .................................... 361 Charge end reason 25 .................................... 217
Fault Reason 0x04faff ...................................... 363 Charge end reason 26 .................................... 219
Fault Reason 0x06faff ...................................... 364 Charge end reason 27 .................................... 221
Fault Reason 0x09faff ...................................... 365 Charge end reason 28 .................................... 223
Fault Reason 0x232802 ................................... 366 Charge end reason 29 .................................... 224
Fault Reason 0x232B01 .................................. 369 Charge end reason 30 .................................... 226
Fault Reason 0x232C01 .................................. 370 Charge end reason 31 .................................... 228
Fault Reason 0x232D09, 0x232E09 ................ 371 Charge end reason 32 .................................... 230
Fault Reason 0x232F01, 0x233001 ................. 372 Charge end reason 33 .................................... 232
Fault Reason 0x234209 ................................... 374 Charge end reason 34 .................................... 234
Fault Reason 0x234309, 0x234409, 0x234509 Charge end reason 35 .................................... 236
...................................................................... 375 Charge end reason 36 .................................... 238
8
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 ................................................ 48
Fault Reason 5 ................................................. 427 Fault Reason 50 ................................................ 52
Fault Reason 6 ................................................. 429 Fault Reason 51 ................................................ 53
Fault Reason 7 ................................................. 430 F0022 .................................................................... 55
Fault Reason 8 ................................................. 431 F0023 .................................................................... 56
Fault Reason 9 ................................................. 432 F0024 .................................................................... 57
Fault Reason 10 ............................................... 433 F0025 .................................................................... 58
Fault Reason 11 ............................................... 434 F0026
Fault Reason 12 ............................................... 435 Fault Reason 1, 2, 3 .......................................... 59
Fault Reason 13 ............................................... 436 Fault Reason 4, 5, 6 .......................................... 61
Fault Reason 14 ............................................... 437 Fault Reason 7 .................................................. 63
Fault Reason 15 ............................................... 441 Fault Reason 8, 9, 10 ........................................ 64
Fault Reason 16 ............................................... 446 Fault Reason 11, 12, 13 .................................... 67
F0009 ................................................................... 451 Fault Reason 14, 15, 16 .................................... 69
F0010 ................................................................... 481 Fault Reason 17 ................................................ 74
F0012 Fault Reason 18, 19, 20 .................................... 75
Fault Reason 4301, 4302 ................................. 498 Fault Reason 22, 23, 24 .................................... 77
Fault Reason 5001 ........................................... 499 Fault Reason 25, 26, 27 .................................... 79
Fault Reason 5102 ........................................... 500 Fault Reason 28 ................................................ 80
Fault Reason 5201 ........................................... 502 Fault Reason 29 ................................................ 81
Fault Reason 5202 ........................................... 504 Fault Reason 30 ................................................ 82
Fault Reason 5401 ........................................... 506 Fault Reason 32, 33, 34 .................................... 84
F0014 Fault Reason 35 ................................................ 86
Fault Reason 0101 ........................................... 482 Fault Reason 36 ................................................ 89
Fault Reason 2403, 2404, 2405, 2406 ............ 483 Fault Reason 37 ................................................ 94
Fault Reason 3602 ........................................... 484 Fault Reason 38 ................................................ 95
Fault Reason 3604 ........................................... 486 Fault Reason 39 ................................................ 96
Fault Reason 3610 ........................................... 489 Fault Reason 40, 41, 42, 43 .............................. 97
Fault Reason 3703, 3704 ................................. 492 Fault Reason 44 ................................................ 99
Fault Reason 3707 ........................................... 486 Fault Reason 45 .............................................. 100
Fault Reason 3802 ........................................... 495 Fault Reason 46 .............................................. 101
Fault Reason 5402 ........................................... 509 Fault Reason 47 .............................................. 102
F0015 ................................................................... 701 Fault Reason 48 .............................................. 105
F0016 ..................................................................... 20 Fault Reason 49–70 ........................................ 107
F0017 ..................................................................... 26 Fault Reason 71 .............................................. 108
F0018 ..................................................................... 28 Fault Reason 73 .............................................. 109
F0019 Fault Reason 74 .............................................. 110
Fault Reason 1 ................................................... 31 Fault Reason 75, 76, 77 .................................. 111
Fault Reason 4 ................................................... 31 Fault Reason 78 .............................................. 112
Fault Reason 10 ................................................. 31 Fault Reason 100 ............................................ 113
Fault Reason 13 ................................................. 31 Fault Reason 102, 103, 104 ............................ 115
Fault Reason 32 ................................................. 32 F0027 .................................................................. 116
Fault Reason 34 ................................................. 33 F0028 .................................................................. 117
Fault Reason 48 ................................................. 35 F0029 .................................................................. 118
Fault Reason 49 ................................................. 36 F0030 .................................................................. 119
F0020 F0032 .................................................................. 120
Fault Reason 2 ................................................... 37 F0033 .................................................................. 121
Fault Reason 5 ................................................... 37 F0034 .................................................................. 122
Fault Reason 11 ................................................. 37 F0035 .................................................................. 123
Fault Reason 14 ................................................. 37 F0036 .................................................................. 124
Fault Reason 19 ................................................. 38 F0037 .................................................................. 125
Fault Reason 21 ................................................. 39 F0038 .................................................................. 126
Fault Reason 22 ................................................. 40 F0039 .................................................................. 127
9
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 .................................................................. 260
F0047 ................................................................... 136 F0132 .................................................................. 512
F0048 ................................................................... 137 F0133 .................................................................. 551
F0049 ................................................................... 138 F0134 .................................................................. 552
F0050 ................................................................... 603 F0135 .................................................................. 553
F0051 ................................................................... 604 F0136 .................................................................. 554
F0052 ................................................................... 604 F0137 .................................................................. 631
F0053 F0139 .................................................................. 707
Fault Reason 1, 2 ............................................. 523 F0140 .................................................................. 403
Fault Reason 3 ................................................. 524 F0141 .................................................................. 562
Fault Reason 4, 5 ............................................. 523 F0142 .................................................................. 565
Fault Reason 6, 7 ............................................. 526 F0143 .................................................................. 570
Fault Reason 8 ................................................. 523 F0144 .................................................................. 452
F0054 ................................................................... 527 F0145 .................................................................. 633
F0055 ................................................................... 535 F0146 .................................................................. 145
F0057 ................................................................... 605 F0147 .................................................................. 635
F0058 ................................................................... 606 F0148 .................................................................. 641
F0059 ................................................................... 672 F0149 .................................................................. 642
F0060 ................................................................... 677 F0150 .................................................................. 643
F0061 ................................................................... 614 F0151 .................................................................. 644
F0062 ................................................................... 614 F0152 .................................................................. 645
F0063 ................................................................... 616 F0153 .................................................................. 147
F0064–F0079 ...................................................... 466 F0154 .................................................................. 148
F0080–F0087 ...................................................... 474 F0155 .................................................................. 149
F0088 ................................................................... 240 F0156
F0092 ................................................................... 618 Signal Validity Code 1, 2 ................................. 646
F0095 ................................................................... 619 Signal Validity Code 12 ................................... 650
F0097, F0098 Signal Validity Code 13, 14, 15 ....................... 652
Fault Reason 1 ................................................. 271 Signal Validity Code 16 ................................... 654
Fault Reason 2 ................................................. 273 Signal Validity Code 17 ................................... 656
Fault Reason 3 ................................................. 277 Signal Validity Code 18 ................................... 659
Fault Reason 4 ................................................. 280 Signal Validity Code 19, 20, 21 ....................... 648
Fault Reason 5 ................................................. 283 Signal Validity Code 22 ................................... 661
Fault Reason 6 ................................................. 284 Signal Validity Code 23 ................................... 663
Fault Reason 7 ................................................. 286 Signal Validity Code 24 ................................... 654
Fault Reason 8 ................................................. 290 Signal Validity Code 25 ................................... 665
Fault Reason 9 ................................................. 293 Signal Validity Code 26, 27, 28 ....................... 661
Fault Reason 10 ............................................... 296 Signal Validity Code 29, 30 ............................. 667
Fault Reason 11 ............................................... 297 Signal Validity Code 3, 4, 5, 6, 7, 8, 9, 10, 11, 03
F0099 ................................................................... 299 ..................................................................... 648
F0100 Signal Validity Code 31 ................................... 646
Fault Reason 1 ................................................. 310 Signal Validity Code 32, 33 ............................. 654
Fault Reason 2 ................................................. 311 Signal Validity Code 34, 35, 36 ....................... 661
Fault Reason 3 ................................................. 315 Signal Validity Code 37, 38, 39 ....................... 654
Fault Reason 4 ................................................. 317 Signal Validity Code 40 ................................... 665
F0102 ................................................................... 318 Signal Validity Code 41 ................................... 656
F0103 ................................................................... 320 Signal Validity Code 42, 43, 44, 45, 46, 47, 48, 49
F0104 ................................................................... 321 ..................................................................... 648
F0105 ................................................................... 536 Signal Validity Code 50 ................................... 652
F0107 ................................................................... 139 F0158 .................................................................. 571
F0108 ................................................................... 627 Heating circuit investigation ................................ 748
10
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 ............................... 691
Radiator Fan 01 no contact ................................. 576 Traction Inverter no contact ................................ 324
Radiator Fan 02 no contact ................................. 583

11
General Information

General Information
PACCAR vehicle Diagnostics

The PACCAR vehicle is driven by an electric The Vehicle Control Unit (VCU) provides self-
powertrain. High voltage batteries supply all onboard diagnosis during operation. If the system detects a
systems. problem, it will display an error message on the
Human-Machine Interface (HMI) to notify the driver.
Various electrical systems are installed on the These error messages are the primary information
vehicle. These systems are interconnected by source to troubleshoot function losses on the
means of low voltage (LV) and high voltage (HV) vehicle.
electrical networks, CAN buses, and hydraulic,
pneumatic, and coolant piping. Operational Data

The HMI is also able to display a variety of key

The vehicle produces its own hydraulic and
operating parameters for vehicle systems and
pneumatic energy onboard as needed.
components such as voltage, temperature, and
power usage. These data can provide useful
Key Features information for troubleshooting.
The vehicle systems include diagnostic capabilities
to help identify and solve problems:
• Diagnostics
• Operational data

12
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
provided in the specific section for each system, The power steering system is an electro-hydraulic
which can be found on the page indicated. system which produces supplemental steering force
to assist the driver in steering the vehicle.
Additional information is also available in the vehicle
service manual. HVAC System … page 522

ESS … page 19 The Heating, Ventilation and Air Conditioning

(HVAC) system provides heating, cooling, and
The Energy Storage System (ESS) is the vehicle ventilation to the driver cab.
battery pack. It includes the Battery Management
System (BMS) and heating and cooling circuits to VCU-HMI System … page 602
help maintain the proper operating temperature in
cold weather. The Vehicle Control Unit (VCU) is the main
processing unit which monitors and controls most of
Charging System … page 161 the systems and equipment on the vehicle. It
interfaces with other equipment either through the
The charging system converts electrical energy input CAN network or by means of dedicated low-voltage
to charge the ESS. It can accept either alternating signals. The Human-Machine Interface (HMI)
current (AC) or direct current (DC) input. The provides a communication interface between the
vehicle is charged using a charger that is attached to VCU and the driver.
the electrical power grid. The charger is referred to
in this manual as an EVSE (Electric Vehicle Supply Powertrain Cooling System … page 671
Equipment).
The cooling system helps to maintain the proper
Propulsion System … page 270 operating temperature for the equipment connected
to the cooling circuit. It consists of a cooling loop,
The propulsion system converts electrical energy radiator, pump, and fans.
from the ESS into mechanical energy to propel the
truck. It consists of an electric motor and a Traction Telemetry System … page 690
inverter. The propulsion system is available in two
configurations medium duty and heavy duty. The telemetry system collects and transmits
operational data from the various vehicle systems to
Brake System … page 325 remote servers where they can be accessed by
operators for monitoring purposes.
The brake system is responsible for stopping the
vehicle. The brakes are operated by compressed air ePTO System … page 700
supplied by an onboard compressor.
The electric power take-off (ePTO) system provides
DCDC System … page 417 an electrical power output which can be used to
operate aftermarket onboard accessories.
The DCDC system accepts high voltage (HV) input
from the ESS and converts it to 24V low voltage (LV) PINOVO+
to charge the two LV batteries, which power the 12V
and 24V equipment throughout the vehicle. Is a separate vehicle controller that comprises two
major function. That of the supervisory controller,
Low Voltage Distribution System … page 465 (FSVCU) where its function is to monitor vehicle
systems on CAN-A, CAN-B, CAN-C, and CAN-D.
The low voltage distribution system distributes 12V Should the selected devices perform an unsafe
and 24V power throughout the vehicle to power function the supervisory controller provides a safe
onboard equipment and accessories. shutdown sequence. The PINOVO+ also functions
as a charge controller, managing the charging
process when the vehicle is connected to an EVSE.

13
Diagnostics

Diagnostics
Fault Codes In the event a service (wrench) or stop (red) lamp is
illuminated on the main instrument cluster of the
The HMI provides various error messages which are truck, check the HMI touch screen to the right of the
the primary means of identifying and troubleshooting steering wheel for any popup messages faults.
problems on the vehicle. When no popup messages are visible, access the
fault log memory of the VCU using the HMI touch
Error messages on the HMI are in the format screen. A fault summary of active DTCs and detailed
fault information for various subsystems may be
Fxxxx - Error message text. accessed by service personnel using the diagnostic
pages of the HMI.
Each message includes a diagnostic error code
which is numbered between F0000 and F9999. Operational Data
Additionally, the HMI provides a short text
description to help the technician understand the The HMI also provides diagnostic screens which are
nature of the problem. accessible to technicians. These screens display the
most important signals of each system, which can be
Fault Reasons useful for troubleshooting.

When variety of related errors are grouped under the An example of a diagnostic screen giving data about
same error code the HMI will provide an additional the ESS is shown here:
fault reason code which gives more information
about the specific cause of the error. The fault
reason appears on the error message under the
main error code:

Fxxxx - Error message text.

Fault Reason 0

The exact text and format of the fault reason

message varies by subsystem.

Fault Log
Multiple error messages may be raised at once.
Some error messages are latching and will remain This illustration is an example and might not
displayed on the HMI until the vehicle is reset by represent the exact display interface of the vehicle.
turning the ignition off and on. Some latching faults
may require a component service tool to reset the Refer to Dana's Diagnostic Guide for more
fault. Other error messages will be cleared as soon information on HMI screen operation and error code
as the underlying fault is resolved. retrieval.

The HMI provides an error log which lists all errors

raised in chronological order. This can be useful
when multiple errors are raised at once or when
error messages have been cleared from the main
HMI display. Note that the Fault codes and reasons
on device faults are time stamped in the VCU fault
log.

The fault code trouble tree should be used for

troubleshooting faults displayed on the HMI or found
in the fault logs.

14
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
• Broken wires
• Open circuits
• Short circuits
• Incorrect battery voltage

15
Diagnostics

Troubleshooting Tips
This checklist outlines some general hints and fixed, be sure to run the system through the same
guidelines that will be helpful in tracking down and operating modes that caused the issue and verify
correcting operating problems. that the error code does not reappear.

Dealing with multiple errors Errors during charging

If multiple errors are raised at once, the If an error was found after the vehicle has been
corresponding error messages will stack on the charging unattended, always consult the fault log to
HMI display with the highest priority message on find all errors raised during the charging session.
top.
Disconnect the Vehicle Control Unit
It is recommended to photograph or otherwise
connector with ignition off
record each error message before clearing it from
the HMI. Then consult the fault log to determine To avoid setting electrical fault codes, make sure
which of these errors was raised first and begin that the ignition is switched off before
troubleshooting by locating the entry for that error. disconnecting the wire harness connection.
Connect the connector before switching on the
Going through the troubleshooting trees ignition.

It is recommended to follow the order of actions

Inspecting wiring for continuity failure
suggested by the troubleshooting trees when
troubleshooting to ensure a systematic process. When inspecting LV, HV, or CAN wiring, continuity
Since systems interact with each other, specific failure includes visible defects like broken cables or
troubleshooting trees might refer to other trees, connector defects. 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. repair or replace the wiring or connectors
accordingly. During inspection of any system
Systems not provided by Dana are not wiring, also pay attention to the system grounding,
covered in this guide it may be a cause of the fault.

Systems that are not provided or selected by Dana

Intermittent faults
are not covered by this troubleshooting guide and
might require use of additional external If an error appears intermittently or if the error
documentation. disappeared on the way to the dealership, gather
as much information as possible about the
Root causes outside the scope of this guide circumstances in which the error appeared and
perform a test drive under similar circumstances to
This guide is meant to cover a dealership / garage see if the error reappears.
level of troubleshooting. Some root causes require
specialized troubleshooting or other support from
Faults that do not appear in the guide
Dana. If the troubleshooting tree does not provide
a solution to troubleshoot or solve an issue, please If any fault appears which is not covered in this
contact Dana for further investigation. guide, please contact Dana for further
investigation.
A cleared code alone does not indicate a
corrected problem

An error code is set by a specific fault condition

and may be cleared by switching the ignition off
and then on. It is possible to clear an error
message only to have it appear again when the
fault condition reoccurs. To make sure an issue is
16
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.
not sure which system the error code belongs to,
consult the Error Code Index at the front of this Each error entry is formatted as shown below:
guide.

Error Code

Error Description Possible Causes Possible Solutions

Details the dysfunctional event that List of the possible root causes List of the possible solutions to
occurs on the unit. that might be the source of the each possible cause (determined
dysfunctional event (determined through the troubleshooting tree).
through the troubleshooting tree).

This section contains any additional information that This section also includes:
is pertinent to troubleshooting the error. This material
is intended to provide context and insight to • Diagrams of any connectors the technician may
accompany the troubleshooting tree. The need to disconnect during troubleshooting.
troubleshooting tree is the main diagnostic • Any relevant note, caution, or warning
procedure the technician should follow. messages.

Troubleshooting Tree

A step-by-step procedure to
guide the technician through the
troubleshooting process.

17
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.

Refers the technician to an external troubleshooting

External process. This can be either another tree within this
Reference guide or an external document such as a supplier
manual.

Refers the technician to a subtree within this guide.

Subtrees cover general procedures which may
apply to many different errors (i.e., troubleshooting
Subtree problems with connectors, relays, or the CAN
Reference network). The subtree entries are at the end of the
guide starting on page 715. After completing the
subtree, the technician should return to the original
tree.

For legibility, some branches of the tree may be split

off to be displayed on a later page. Split branches
are labeled alphabetically (A, B, C…). When a
Split branch terminates in (A), the technician should
locate the corresponding (A) indicator on a
subsequent page of the tree and continue
troubleshooting.

18
Troubleshooting

ESS
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.
The chiller uses a refrigeration cycle to remove heat
Component descriptions from the ESS coolant circuit. It is powered by 24V
low voltage and communicates via the CAN network.
High Voltage Batteries It also receives analog feedback from a coolant level
sensor in the coolant reservoir. The chiller includes
The high voltage batteries are available in three the Thermal Management System (TMS) which
configurations: 141 kWh, 209 kWh, and 282 kWh. manages the battery temperature.

In the 141 kWh configuration, the ESS consists of Chiller Tank

two battery packs designated Pack 1 and Pack 2. In
the 282 kWh configuration, the ESS consists of four The chiller tank is the reservoir for the ESS cooling
packs designated Pack 1 through Pack 4. Each system. It has an internal sensor which reports the
battery pack includes an internal heating circuit and fluid level to the chiller.
cooling loop. The layout of the 209 kWh option is not
yet defined. Cooling Circuit

S-Box The cooling circuit runs through each ESS battery

pack. For the 141 kWh ESS configuration, there is a
The S-Box is the interface between the ESS and the single cooling loop which runs through both battery
other vehicle systems. It includes the Battery packs. For the 282 kWh configuration, there are two
Management System (BMS) which manages and parallel cooling loops which each run through two of
balances the charging and discharging of the the four battery packs. The layout of the 209 kWh
batteries. option is not yet defined.

ESS Cooling System Warning: The high voltage batteries are

NOT serviceable and should NEVER be
The ESS cooling system helps to maintain the opened. Only the MSDs and HV cable
proper operating temperature in the ESS. It uses a connections should be accessed according
chiller and pump to circulate coolant through the to repair and safety procedures.

19
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.

3) Defective relay K007. 3) Replace relay K007.

4) Loss of continuity due to 4) Repair or replace LV

defective LV connector or connector or harness.
harness.
5) Repair or replace cut loop
5) Cut loop broken or faulty cut wiring.
loop wiring.
6) Resolve CAN communication
6) CAN communication problem. problem.

7) Shutdown requested by 7) Troubleshoot specific error.

powertrain safety system.
8) Troubleshoot specific error.
8) Loss of power to MPDM or
MPDM internal failure. 9) Replace VCU.

9) VCU internal failure.

Connector C44
Connector C11 (black)

Connector C50
Connector C40

20
Troubleshooting

Connector C93S (socket)

Connector C53

Connector C76

Connector C367P (pin)

Connector C93P (pin)

Connector C367S (socket)

21
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 Yes Repair according to the

Is the error code still
problem in the CAN A or C actions prescribed in the
displayed?
network? subtree.

Yes
No

Does the HMI also Yes

Refer to the MPDM No contact
display “MPDM No
troubleshooting tree.
contact”?

Yes
Does the HMI also Refer to error F0080
display F0080? troubleshooting tree.

Yes
Does the HMI also Refer to error F0085
display F0085? troubleshooting tree.

No Continued on next page

22
Troubleshooting

No
Continued from previous page

Yes
Does the HMI also Refer to error F0058
display F0058? troubleshooting tree.

Yes
Does the HMI also Refer to error F0147
display F0147? troubleshooting tree.

Yes
Does the HMI also Refer to error F0051
display F0051? troubleshooting tree.

Yes
Does the HMI also Refer to error F0052
display F0052? troubleshooting tree.

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Refer to relay Is there any evidence of a Yes

Defective relay.
investigation subtree. defect between the pins of
Replace relay.
Investigate relay K007. the relay?

No
Continued on next page
23
Troubleshooting

No 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 Yes Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No
With a multimeter, check for continuity between the
following points:
MPDM C11 C93P
Connector pin Connector pin
Pin D Pin 5
MPDM C11 C40S
Connector pin Connector pin
Pin G Pin 12

C93S C76
Connector pin Connector pin
Pin 6 Pin 4

Pin 5 Pin 1

C93P C40S
Connector pin Connector pin
Pin 6 Pin 9

C40P C367S
Connector pin Connector pin

Pin 9 Pin 11

Pin 12 Pin 12

C44 S-Box C367S

Connector pin Connector pin
Pin 14 Pin 12

Pin 13 Pin 11

C76 C40S
Connector pin Connector pin
Pin 2 Pin 30

C40P C50S
Connector pin Connector pin
Pin 30 Pin N

12V fuse box C14 C9 C76

Terminal Connector pin
C9 Pin 5

C50P C53
Connector pin Connector pin
Pin N Pin H1

- Continuity : Resistance is less than or equal to 2ohms.

24
Continued on next page
Troubleshooting

Continued from previous page

Yes
Is there any evidence Defective harness.
of a continuity loss? Replace harness.

Defective supervisory controller.

Replace supervisory controller.

Is the error still Yes

occurring on further Contact Dana for further
key ON or charge investigation.
cycles?

Complete

25
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.
3) Replace HV fuse F8.

This error indicates that the VCU has detected that precharge as failed and the vehicle startup will be
the HV distribution system has not reached the aborted.
required voltage to pass the precharge stage and
therefore the vehicle is unable to start. The high voltage value used by the VCU to make
this determination is measured and reported by the
The precharge circuit manages the voltage ramp-up DCDC. The vehicle will not be able to pass
of the HV system upon startup of the vehicle. precharge if the VCU loses contact with the DCDC.
Precharge ends when the voltage of the HV
distribution system reaches 95% of the ESS voltage. If error F0017 occurs more than 3 times, the VCU
The vehicle is then enabled to start. If the HV will also raise error F0018.
distribution system fails to reach the required
threshold within 5 seconds, the VCU will flag

26
Troubleshooting

HMI displays or logs

Fault code F0017

Yes
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.

Yes Is there still a precharge No

Was there a defect on CAN
error on further truck Complete
A or CAN D networks?
ignitions?

Yes

Observing proper safety

precautions, open the HV
junction box.
WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual Inspect HV fuse F8 in the HV
and Diagnostic Guide. junction box.

Yes 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.
27
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.

This error is raised when the “precharge failed” error The high voltage value used by the VCU to make
(F0017) has occurred more than 3 times and this determination is measured and reported by the
therefore the vehicle is unable to start. DCDC. The vehicle will not be able to pass
precharge if the VCU loses contact with the DCDC.

28
Troubleshooting

HMI displays or logs

Fault code F0018

Yes
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.

Yes Is there still a precharge No

Was there a defect on CAN
error on further truck Complete
A or CAN D networks?
ignitions?

Yes

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Continued on next page

29
Troubleshooting

Continued from previous page

Observing proper safety

precautions, open the HV
junction box.

Inspect HV fuse F8 in the HV

junction box.

Yes 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.

No
Is the error persisting ? Complete

Yes

Contact Dana for further

investigation.

30
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.

Replace Battery TMS.

31
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. (F0026) and VCU (F0017) if Battery TMS fault
Precharge ends when the voltage of the HV reason 32 appears.
distribution system reaches 95% of the ESS voltage.
The vehicle is then enabled to start. If the HV
distribution system fails to reach the required
threshold within 5 seconds, the VCU will flag
precharge as failed and the vehicle startup will be
aborted.

HMI displays or logs

Fault code F0019 and
TMS fault reason 32

Does the HMI also Yes Refer to F0017 troubleshooting

display F0017? tree.

Does the HMI also Yes Refer to the corresponding

display F0026? troubleshooting tree.

Defective Battery TMS.

Replace Battery TMS.

32
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.

This error could be raised due to some momentary

spikes on the HV bus.

33
Troubleshooting

HMI displays or logs

Fault code F0019 and
TMS fault reason 34

Is any other system on the Yes Yes

Does the HMI also display Refer to the corresponding
HV DC bus raising an
F0026? error troubleshooting tree.
overvoltage error?

No No

Contact Dana for further

investigation.
WARNING: Electrical hazard.

Follow Safety Warnings and High With a multimeter, check for continuity between the
Voltage Shutdown Procedures following points:
defined in the Service Manual
and Diagnostic Guide. RT063 RT064
Connector pin Connector pin
RT063 RT064

Disconnect connector RT063 - Continuity : Resistance is less than or equal to 2ohms.

from Battery TMS.
Disconnect connector RT064
from HV junction box.

Check the connectors for

corrosion, scorching, or physical
integrity loss. Is there any evidence of a Yes Defective harness.
continuity loss in the
Replace harness.
harness?

Contact Dana for further

investigation.

34
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.

This error indicates that the TMS has reported that it

has lost communication with the BMS and is no
longer receiving control input.

HMI displays or logs

Fault code F0019 and
TMS fault reason 48

Does the HMI also Yes Refer to the BMS No contact

display “BMS No
troubleshooting tree.
contact”?

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 harness per Service Manual.
or harness.
3) Replace coolant level sensor.
3) Defective coolant level sensor.

Error F0119 is expected to be raised at the same

time as this error.

Connector C40

Connector C39

Connector C46

44
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.

No
Is the chiller tank liquid
level low? A

Yes

Check the chiller tank for

potential leaks.

Continued on next page

45
Troubleshooting

Continued from previous page

Yes Replace the cooling tank

Are there any leaks in the
according to the service
cooling tank?
manual instructions.

Inspect ESS cooling circuit

hoses for leaks.

Yes Replace faulty cooling hoses

Are there any leaks in the
according to the service
ESS cooling circuit?
manual instructions.

Open the ESS cover panel in

order to check for potential
leaks in the ESS cooling
circuit inside the ESS.

Yes Replace faulty cooling hoses

Are there any leaks in the
according to the service
ESS cooling circuit?
manual instructions.

Contact Dana for

further investigation.

46
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 Yes the connector
Service Chart” in the Service Manual integrity?

With a multimeter, check for continuity between the

following points:

C40 Tank C39

Connector pin Connector pin
Pin 35 Pin 1

Pin 36 Pin 2

C40 TMS C46

Connector pin Connector pin

Pin 35 Pin 1

Pin 36 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

Defective harness. Yes Is there any evidence of

Replace harness. a continuity loss?

Defective level sensor.

Replace level sensor.

47
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. 3) Replace MPDM relay K7.

4) Blown 24V fuse F1. 4) Replace 24V fuse F1.

5) Loss of continuity due to 5) Replace LV connector or

defective LV connector or harness per Service Manual.
harness.
6) Replace TMS.
6) TMS internal failure.

Connector C11 (black)

Connector C45

Connector C40

Connector C100

48
Troubleshooting

HMI displays or logs

Fault code F0020 and
TMS fault reason 47

Does the HMI also display Yes Refer to the corresponding

F0008 or F0095? troubleshooting tree.

Does the HMI also Yes Refer to the F0086

display F0086? troubleshooting tree.

Does the HMI also Yes Refer to the F0066

display F0066? troubleshooting tree.

A
Inspect fuse F1 from 24V Is fuse F1 blown or Yes
fuse box C20. intermittent?

Disconnect connector C40.

Disconnect connector C11 from MPDM.
Disconnect connector C45 from TMS. No
Remove fuse F1 in order to take
continuity measures from inside
the fuse box.

Continued on next page

49
Troubleshooting

Continued from previous page

Refer to the connector integrity

investigation subtree.

Is there Defective connector.

any problem with Yes 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 C40S
Terminal Connector pin
A1 Pin 14

C40P TMS C45

Connector pin Connector pin

Pin 15 Pin 12

Pin 14 Pin 11

Pin 13 Pin 5

C40S TMS C100

Connector pin Connector pin

Pin 15 Pin 9
MPDM C11 TMS C40S
Connector pin Connector pin

Pin F Pin 13

- Continuity : Resistance is less than or equal to 2ohms.

Is there any evidence Yes Defective harness.

of a continuity loss? Replace harness.

Defective Battery TMS.

Replace Battery TMS.
50
Troubleshooting

Complete
A No

Replace fuse F1 on 24V fuse box

Disconnect blown fuse F1 from Did fuse F1 blow again
C20.
24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and Yes

Disconnect Connector C45 from
disconnect F1 from 24V fuse box
Battery TMS.
C20.

Refer to connector integrity inspection

subtree.

Is there Defective connector.

any problem with Yes Replace the connector as described in the “Wire
the connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No Defective harness.
Replace harness.

With a multimeter, check for short circuit between No

the following points:
24V fuse box C20
Ground
Terminal Is there any
A1 Ground evidence of a short
circuit within the
-LV short: Resistance measurement is less than 100k- harness?
ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.
Yes

Did fuse F1 blow Replace fuse F1 on 24V fuse box

Complete again during test C20.
No drive? Restart the vehicle.

Yes

Contact Dana for further

investigation.

51
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.

Replace Battery TMS.

52
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.

This error could be raised due to some momentary

spikes on the HV bus.

53
Troubleshooting

HMI displays or logs

Fault code F0020 and
TMS fault reason 51

Is any other system on the Yes Yes

Does the HMI also display Refer to the corresponding
HV DC bus raising an
F0026? error troubleshooting tree.
overvoltage error?

No
No

Contact Dana for further

investigation.

WARNING: Electrical hazard. With a multimeter, check for continuity between the
following points:
Follow Safety Warnings and High
Voltage Shutdown Procedures RT063 RT064
defined in the Service Manual Connector pin Connector pin
and Diagnostic Guide.
RT063 RT064

- Continuity : Resistance is less than or equal to 2ohms.

Disconnect connector RT063 from

Battery TMS.
Disconnect connector RT064 from HV
junction box.

Check the connector for corrosion, Is there any

evidence of a Yes Defective harness.
scorching, or physical integrity loss.
continuity loss in the Replace harness.
harness?

Contact Dana for further

investigation.

54
Troubleshooting

F0022 - High Voltage system fault

Error Description Possible Causes Possible Solutions

BMS or VCU has detected a HV 1) Defective charger 1) Use a different charger

system isolation fault.
2) HV system isolation fault 2) Contact Dana

In the event of a genuine HV system isolation fault, Warning: HV system isolation fault can
one or more of F0026 (BMS fault reason 40, 41, 42, pose an extreme hazard and may result in
or 43), F0035, F0036, F0037, or F0038 is also high voltage being present in parts of the
expected to appear. If F0022 appears alone, there vehicle that are not normally energized. 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

Yes
Is error F0026 BMS (40, 41, 42,43) Refer to the corresponding error
also present? troubleshooting tree.

Contact Dana for further

investigation.

55
Troubleshooting

F0023 - Vehicle Performance Limited by Battery System

Error Description Possible Causes Possible Solutions

BMS derates high voltage power. 1) ESS fault. 1) Troubleshoot specific error.

The BMS derates high voltage power in response to requested. The BMS will request limp mode in
certain faults. F0023 is triggered if the BMS requests response to fault reason 28, 44, 45, 47, 48, 52, 54,
limp mode, meaning the vehicle is still drivable under 56, 58, 60, 62, 64, 66, 68, or 70, and will request
very restricted conditions, or requests driving to be driving to be disabled in response to fault reason 5,
disabled entirely. The error is also triggered if the 6, 7, 12, 13, 15, 16, 29, 37, 41, or 42. If the SOC falls
ESS state of charge (SOC) falls below 12%. In this below 12%, BMS fault reason 33 or 34 will be raised.
case the high voltage power will be limited to 50%.
If error F0023 appears without one of the listed
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

Fault code F0023

Yes
Is F0026 BMS 32 Refer to error F0026 BMS32
displayed on the HMI? troubleshooting tree.

Is F0026 BMS 4, 11, 14, 22, Yes

23, 24, 28, 33, 34, 40, 44, 45, 47, 48, Refer to the corresponding error
52, 54, 56, 58, 60, 62, 64, 66, 68, 70 troubleshooting tree.
displayed on the HMI?

Contact Dana for further

investigation.

56
Troubleshooting

F0024 - Regenerative Braking reduced

Error Description Possible Causes Possible Solutions

Regenerative braking power has 1) High state of charge (SOC). 1) No action needed if fault code
been limited. occurs alone.
2) ESS fault.
2) Troubleshoot specific error.

The BMS requests a limitation of the regenerative in response to fault reason 1, 2, 3, 7, 9, 10, 15, 16,
braking power in response to certain faults. F0024 is 26, 27, 28, 29, 37, 41, 42, 44, 45, 47, 48, 103, or
triggered if the BMS requests a limitation of the 104.
regenerative braking power to 25% or requests
regenerative braking to be disabled entirely. Regenerative braking may be disabled or reduced if
the ESS state of charge (SOC) is close to 100% to
This error is expected to be accompanied by error avoid overcharging the ESS.
F0026 which provides a BMS fault reason code
indicating the specific reason the limitation was If error F0024 appears without one of the listed
requested. The BMS will request regenerative 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.
and will request regenerative braking to be disabled

HMI displays or logs

Fault code F0024

Are there also BMS No

Complete
faults found?

Yes

Is F0026 BMS 52, 54, 56, Yes

Refer to the corresponding error
58, 60, 62, 64, 66 ,68 ,70
troubleshooting tree.
displayed or logged?

Contact Dana for further

investigation.

57
Troubleshooting

F0025 - Regenerative Braking reduced

Error Description Possible Causes Possible Solutions

Limitation of the regenerative 1) State of charge (SOC) close to 1) No action needed; this is the
braking power is active or has 100%. intended vehicle function.
been requested by the BMS.
2) ESS fault. 2) Troubleshoot specific error.

The BMS requests a limitation of the regenerative Regenerative braking may be disabled or reduced if
braking power in response to certain faults. F0025 is the ESS state of charge (SOC) is close to 100% to
triggered if the BMS requests a limitation of the avoid overcharging the ESS.
regenerative braking power to 50%.
If error F0025 appears without one of the listed
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.
requested. The BMS will request regenerative
braking power to be limited to 50% in response to
fault reason 8, 14, 25, 40, or 102.

HMI displays or logs

Fault code F0025

Does the HMI also Yes

Refer to the corresponding error
display BMS 8/14/25/
troubleshooting tree.
40/102?

Is the HMI displaying BMS Yes

1/2/3 or is F0025 occurring Complete
when SOC is near 100%?

Contact Dana for further

investigation.

58
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. If one of these errors is raised, by allowing the ESS to rest for a period or by
regenerative braking will be disabled and charging discharging and recharging it. If these procedures
will be terminated. are unsuccessful, the ESS may be defective.

HMI displays or logs

Fault code F0026 and
BMS fault reason 1/2/3

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.

Is the error message No

still displayed on the Complete
HMI?

Yes

Access the HMI and check the

maximum cell voltage in the
ESS diagnostic page.

Continued on next page

59
Troubleshooting

Continued from previous page

Is the maximum Yes

Contact Dana for further
cell voltage over
investigation.
3.7V?

No
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.

Yes
Is the message reappearing Contact Dana for further
during charge? investigation.

Complete

60
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

increasing severity. If fault reason 4 is raised, the Note: For best ESS performance and
high voltage power will be limited to 50%. If fault vehicle range HV batteries must regularly be
reason 5 is raised, driving will be disabled. If fault changed to 100% SOC. Vehicle SOC is a
reason 6 is raised, the BMS will request the vehicle calculated valued that drifts over time. It is
to shut down. recalibrated only at the end of the charge
cycle when HV batteries are charged to
Note: If requested during this procedure to 100%. Always fully change the vehicle until
connect the vehicle to a charger, a level 2 the charge cycle automatically ends. Only
charger is required. charge vehicle using a level 2 or level 3
EVSE.
Note: Make sure HV systems are not in use
while charging.

61
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 4/5/6

Unplug EVSE from the truck if Turn ignition OFF and switch Wait one hour before taking
applicable. OFF LOTO switch. any further action.

Turn the truck back ON in

accessory mode.

Access the HMI and check the Yes No

Is the error message still Plug in EVSE and charge to
minimum cell voltage in the
displayed on the HMI? 100%.
ESS diagnostic page.

Yes
Is the minimum cell Contact Dana for further
voltage under 2.3 V? investigation.

Yes
Is the lowest cell voltage Use service procedure for
under 2.5 V? overriding safety controller.

Plug in only a level 2 AC charger.

Charge vehicle until charge cycle
automatically ends.

62
Troubleshooting

F0026 (Fault Reason 7)

Error Description Possible Causes Possible Solutions

BMS has detected an extreme 1) ESS internal failure. 1) Contact Dana.

undervoltage in one or more cells.

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.
and charging will be immediately 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 7

Contact Dana for further

investigation.

63
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.

Fault reasons 8, 9, and 10 are numbered in order of It may be possible to resolve a moderate overvoltage
increasing severity. If fault reason 8 is raised, by allowing the ESS to rest for a period or by
regenerative braking power will be limited to 50%. If discharging and recharging it. If these procedures
fault reason 9 or 10 is raised, regenerative braking are unsuccessful, the ESS may be defective.
will be disabled. If the vehicle is charging, charging
will be terminated.

64
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.

Yes
Is error F0026 BMS 1, 2, or Refer to the corresponding error
3 displayed on the HMI? troubleshooting tree.

Is the error
No
message still
Complete
displayed on the
HMI?

Yes

Access the HMI and check the

minimum cell voltage in the
ESS diagnostic page.

Continued on next page

65
Troubleshooting

Continued from previous page

Yes
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.

Is the SOC under 96% and Yes

Contact Dana for further
the maximum cell voltage
investigation.
under 3.5V?

Yes
Plug in a level 2 AC charger Is the message reappearing Contact Dana for further
and fully charge the truck. during charge? investigation.

Complete

66
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%.

Fault reasons 11, 12, and 13 are numbered in order Note: Make sure HV systems are not in use
of increasing severity. If fault reason 11 is raised, the while charging.
high voltage power will be limited to 50%. If fault
reason 12 is raised, driving will be disabled. If fault
reason 13 is raised, the BMS will request the vehicle
to shut down.

67
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 11/12/13

Unplug EVSE from the truck if Turn ignition OFF and switch Wait one hour before taking
applicable. OFF LOTO switch. any further action.

Is the error
Access the HMI and check the Yes message still Turn the truck back ON in
minimum cell voltage in the
displayed on the accessory mode.
ESS diagnostic page.
HMI?

Plug in EVSE and charge to

100%.

Is the lowest pack Yes

Contact Dana for further
voltage under
investigation.
441.6 V?

Is the lowest pack Yes

Use service procedure for
voltage between
overriding safety controller.
441.6 V and
480 V?

Plug in a level 2 or level 3 charger.

Charge vehicle until charge cycle
automatically ends.

68
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. coolant.

3) Short circuit of coolant tank 3) Replace LV harness or level

level sensor. sensor.

Fault reasons 14, 15, and 16 are numbered in order

of increasing severity:

Fault Reason Maximum Cell Temperature

14 ≥ 140°F (60°C)

15 ≥ 149°F (65°C)

16 ≥ 153°F (67°C)

If fault reason 14 is raised, the high voltage power

and regenerative braking power will be limited to
50%. If fault reason 15 is raised, driving and
regenerative braking will be disabled and charging
will be terminated. If fault reason 16 is raised, the
BMS will request the vehicle to shut down and
charging will be terminated. Connector C39

Warning: Fire hazard. Until the error is

resolved, park the vehicle outside in an open
area away from combustible materials.

Connector C40

Connector C46

69
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. ambient temperature with a thermal
infrared camera.

Yes
Does the HMI also display Refer to error F0045
F0045? troubleshooting tree.

Yes
Does the HMI also display Refer to the corresponding
F0019 or error F0020? troubleshooting tree.

Yes
Does the HMI also display Refer to the Chiller No contact
“Chiller No contact”? troubleshooting tree.

Continued on next page

70
Troubleshooting

Continued from previous page

Refer to the CAN investigation subtree.

Investigate CAN A and CAN B networks.

Was a problem found Yes Repair according to the

with either CAN A or actions prescribed in the
CAN B network? subtree.

Yes
Is the error persisting?

Wait for the cooling liquid to

cool down and check the No
chiller tank liquid level with
the reservoir cap open.

Complete

No
Is the chiller tank liquid
level low? A
Yes

Check the chiller tank for

potential leaks.

Continued on next page

71
Troubleshooting

Continued from previous page

Yes Replace the cooling tank

Is there any leaks in the
following the maintenance
cooling tank?
manual instructions.

Inspect the ESS cooling circuit

hoses for leaks.

Yes Replace the faulty cooling

Is there any leaks in the pipes following the
ESS cooling circuit? maintenance manual
instructions.

Open the ESS cover panel in

order to check for potential
leaks in the ESS cooling
circuit inside the ESS.

Yes Replace the faulty cooling

Is there any leak in the pipes following the
ESS cooling circuit? maintenance manual
instructions.

Contact Dana for further

investigation.

72
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 Yes connector
Service Chart” in the Service Manual integrity?

With a multimeter, check for continuity between the

following points:

Cradle C40 Tank C39

Connector pin Connector pin
Pin 35 Pin 1

Pin 36 Pin 2

Cradle C40 Chiller C46

Connector pin Connector pin

Pin 35 Pin 1

Pin 36 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

Defective harness. Yes Is there any evidence of

Replace harness. a continuity loss?

Defective level sensor.

Replace level sensor.

73
Troubleshooting

F0026 (Fault Reason 17)

Error Description Possible Causes Possible Solutions

BMS has detected that the 1) Low ambient temperature. 1) Troubleshoot the error.
temperature in one or more cells is
too low.

The temperature threshold for this error is -31°F

(-35°C).

HMI displays or logs

Fault code F0026 and
BMS fault reason 17

Was the vehicle No Turn vehicle ON in ready mode for

trying to be operated or 1 hour or charge vehicle for at
charged below -35°C? least one hour.

Yes Charge vehicle if SOC is

below 30%.

HV batteries do not function

below -35°C.

Move the vehicle to a location No

where ambient temperature is Does the fault code
Complete
above 0°C. Allow batteries to reappear?
warm to greater than -25°C.

Yes

Yes
Does the fault code Contact DANA for
reappear? further investigation.

Complete

74
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
ESS is too large. temperature in one or more cells is too high.

Fault reasons 18, 19, and 20 are numbered in order The error may resolve on its own by allowing the
of increasing severity. ESS to cool down.

75
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 18/19/20

Yes
Does the HMI also display Refer to the corresponding
F0026 BMS 14/15/16? error troubleshooting tree.

Yes
Does the HMI also display 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 Yes

Contact Dana for further
displayed on the HMI
investigation.
intermittently?

Complete

76
Troubleshooting

F0026 (Fault Reason 22, 23, 24)

Error Description Possible Causes Possible Solutions

BMS has detected an overcurrent 1) Adverse driving conditions. 1) No action needed.

while the ESS is discharging.
2) Short circuit in HV connector 2) Replace HV harness.
or harness
3) Use fuses with correct current
3) Incorrect HV fuse(s) in HV rating.
junction box.

Fault reasons 22, 23, and 24 are numbered in order

of increasing severity. If any of these errors are
raised, the high voltage power will be limited to 50%.

This error could be caused by a short circuit in the

HV wiring between the S-Box and high voltage
junction box. If this is the case, one or more of Error
F0026 (BMS fault reason 40, 41, or 42), F0035,
F0036, or F0037 should also appear. If none of
these errors are present, it is possible that a fuse
with the wrong current rating was installed in the HV
junction box.
Connector C716 (black)
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)

77
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 22/23/24

Did fault occur Are these fault codes Yes

No
while vehicle was also present; F0022,
transporting a heavy F0035, F0036, F0037 or
load uphill? F0051 Reason 14?

Yes
No

Contact Dana for further

investigation.

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Open the HV junction box per

instructions in the service manual.
Inspect for blown HV fuses.

Replace blown fuse and Yes Are there blown HV fuses in

Contact DANA for further
the HV junction box?
investigation.

Contact Dana for further

investigation.

78
Troubleshooting

F0026 (Fault Reason 25, 26, 27)

Error Description Possible Causes Possible Solutions

BMS has detected an overcurrent 1) Vehicle improperly towed 1) Contact Dana

Note: For best ESS performance and

vehicle range HV batteries must regularly be Note: If requested during this procedure to
changed to 100% SOC. Vehicle SOC is a connect the vehicle to a charger, a level 2
calculated valued that drifts over time. It is charger is required.
recalibrated only at the end of the charge
cycle when HV batteries are charged to Note: Make sure HV systems are off while
100%. Always fully change the vehicle until charging. Vehicle turned off.
the charge cycle automatically ends. Only
charge vehicle using a level 2 or level 3
EVSE.

82
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 30

Yes
Does the HMI also display Refer to the specific error
F0026 BMS 1/2/3/4/5/6? troubleshooting tree.

Turn on heater to discharge HV

Unplug EVSE from the truck if
batteries until the maximum
applicable.
cell voltage is less than 3.25V.

Wait one hour before taking 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.

No
Is the fault code
Complete
still present?

Yes

Contact Dana for further

investigation.

83
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%.

Fault reasons 32, 33, and 34 are numbered in order Note: For best ESS performance and
of increasing severity. vehicle range HV batteries must regularly be
changed to 100% SOC. Vehicle SOC is a
calculated valued that drifts over time. It is
Fault Reason SOC recalibrated only at the end of the charge
cycle when HV batteries are charged to
32 ≤ 20% 100%. Always fully change the vehicle until
the charge cycle automatically ends. Only
33 ≤ 12% charge vehicle using a level 2 or level 3
EVSE.
34 ≤ 8%
Note: Make sure HV systems are off while
charging. Vehicle turned off.
If one of these errors is raised, the high voltage
power will be limited to 50%.

This error may be resolved by connecting the vehicle

to a charger and charging the HV batteries to 100%
SOC.

84
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 32/33/34

Unplug EVSE from the truck if Turn ignition OFF and switch
applicable. OFF LOTO switch.

Wait one hour before taking

Turn ON LOTO switch.
any further action.

Plug in a level 2 or
Access the HMI and check the Yes No
Is the fault still level 3 charger.
minimum cell voltage in the
present? Charge vehicle until charge
ESS diagnostic page.
cycle automatically ends.

Yes
Is the minimum cell Contact Dana for further
voltage under 2.3 V? investigation.

Yes
Is the lowest cell Use service procedure for
voltage under 2.5 V? overriding safety controller.

Plug in a level 2 or
level 3 charger.
Charge vehicle until charge
cycle automatically ends.

85
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.
system.
3) Resolve CAN communication
3) CAN communication problem. problem.

This error indicates that the BMS has detected a Note: Troubleshooting this error may require
problem with the ESS cooling system. The error is the technician to remove the cover that
triggered when the BMS receives a fault message protects the high voltage batteries to inspect
from the battery thermal management system the cooling circuit. The orange high voltage
(BTMS) or detects that the ESS coolant temperature cables in the area are always live. But
is abnormal. accessing the ESS cooling circuit after
removing the cover does not expose the
This error may also trigger F0107. technician to high voltage energy. If the
repair requires removing HV cables or
MSD’s, PPE is required.

86
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 35

Does the HMI also Yes Refer to corresponding error

display any Battery
troubleshooting tree.
TMS related error?

Does the HMI also Yes Refer to error F0026 BMS 44

display F0026
troubleshooting tree.
BMS 44?

Does the HMI also Yes Refer to the specific error

display F0019 or
troubleshooting tree.
F0020?

Does the HMI also Yes

Refer to the Battery TMS No
display “Battery TMS No
contact troubleshooting tree.
contact”?

Refer to the CAN investigation subtree.

Investigate CAN A and CAN B network.

Continued on next page

87
Troubleshooting

Continued from previous page

Could you find a Yes Repair according to the

problem with the CAN A actions prescribed in the
or CAN B network? subtree.

No
Yes Is the error still being
raised on further key ON
cycles?

Dismount the ESS dust cover to

inspect the cooling piping for No
possible leaks, clogging or flow
reduction. Refer to the
Complete
maintenance manual to access
the piping.

Is there any evidence Yes Repair the defect as per

of a defect causing a the maintenance manual
cooling reduction? instructions.

Inspect the rest of the ESS cooling

circuit for leaks, clogs or possible
flow reduction.

Is there any evidence Yes Repair the defect as per

of a defect causing a the maintenance manual
cooling reduction? instructions.

Contact Dana for further

investigation.

88
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. If there is a battery pack will need to be replaced.
problem with the heating circuit, it is either internal to
a battery pack or is within the wiring harness
between the S-Box and battery pack.

HMI displays or logs

Fault code F0026 and
BMS fault reason 36

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Remove dust shield from ESS.

141kWh 282kWh
Which ESS option is
installed on the truck?

A B

89
Troubleshooting

A
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.

Yes
Is there a problem Defective connector.
with any heater cable Replace harness.
connector?

With a multimeter measure the resistance between the

following pack heater connectors on the battery packs :

Pack 1 C785 Pack 1 C786

Connector Connector
Pin 1 Pin 1

Pack 2 C783 Pack 2 C784

Connector Connector
Pin 1 Pin 1

The measured resistance should be between

4 ohms and 6 ohms.

Continued on next page

90
Troubleshooting

Continued from previous page

Is there any evidence of a Yes

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

Connector Connector
Pin 1 Pin 1

S-Box C782P Pack 2 C783P

Connector Connector
Pin 1 Pin 1

Pack 1 C785P Pack 2 C784P

Connector Connector
Pin 1 Pin 1

- Continuity : Resistance is less than or equal to 2ohms.

Yes
Is there any evidence Defective harness.
of a continuity loss? Replace harness.

Contact Dana for further

investigation.

91
Troubleshooting

B
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

subtree.

Yes
Is there a problem Defective connector.
with any heater cable Replace harness.
connector?

With a multimeter measure the resistance between the

following connectors on the battery packs :

Pack 1 C768 Pack 1 C771

Connector Connector
Pin 1 Pin 1

Pack 2 C767 Pack 2 C766

Connector Connector
Pin 1 Pin 1
Pack 3 C764 Pack 3 C761
Connector Connector
Pin 1 Pin 1

Pack 4 C770 Pack 4 C763

Connector Connector
Pin 1 Pin 1

The measured resistance should be between

4 ohms and 6 ohms.

Continued on next page

92
Troubleshooting

Continued from previous page

Is there any evidence of a Yes

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

Connector Connector
Pin 1 Pin 1

Pack 1 C768P Pack 2 C767P

Connector Connector
Pin 1 Pin 1

Pack 2 C766P S-box C765P

Connector Connector
Pin 1 Pin 1

S-box C769P Pack 4 C770P

Connector Connector
Pin 1 Pin 1
Pack 3 C764P Pack 4 C763P
Connector Connector
Pin 1 Pin 1
Pack 3 C761P S-Box C762
Connector Connector
Pin 1 Pin 1

- Continuity : Resistance is less than or equal to 2ohms.

No Yes
Contact Dana for further Is there any evidence Defective harness.
investigation. of a continuity loss? Replace harness.

93
Troubleshooting

F0026 (Fault Reason 37)

Error Description Possible Causes Possible Solutions

BMS has detected extreme 1) ESS internal failure. 1) Contact Dana.

overvoltage, extreme
undervoltage, or extreme
overtemperature in the ESS.

This error indicates that the BMS has detected a If this error is raised, the BMS will request the
severe problem that could cause harm to the ESS vehicle to shut down and charging will be terminated
(extreme overvoltage, extreme undervoltage, or immediately. The vehicle will not be able to restart
extreme overtemperature). If this error appears, until the error is resolved.
contact Dana for specialized troubleshooting.
Warning: Fire hazard. Until the error is
resolved, park the vehicle outside in an open
area away from combustible materials.

HMI displays or logs

Fault code F0026 and
BMS fault reason 37

For safety measure make sure that

the truck is parked outside when this
occurs.

Does the HMI also Yes Refer to corresponding error

display any BMS
troubleshooting tree.
related error?

Contact Dana as soon as possible for

further investigation.

94
Troubleshooting

F0026 (Fault Reason 38)

Error Description Possible Causes Possible Solutions

BMS has detected that the HV 1) ESS fault. 1) Troubleshoot specific error.
system has failed to pass the
precharge stage.

The precharge circuit manages the voltage ramp-up The VCU independently monitors the precharge and
of the HV system upon startup of the vehicle. will raise its own error F0017 if it detects that
Precharge ends when the voltage of the HV precharge has failed. Error F0018 may also appear if
distribution system reaches 95% of the ESS voltage. precharge has failed more than 3 times. If error
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.
aborted.

Fault reason 38 is raised by the BMS when the

voltage ramp-up exceeds the required time limit, a
short circuit or overcurrent is detected in the
precharge circuit, or the BMS fails to complete its
internal pre-check. The BMS will prevent the vehicle
from starting.

HMI displays or logs

Fault code F0026 and
BMS fault reason 38

Does the HMI also Yes Refer to the specific error

display F0017 or
troubleshooting tree.
F0018?

Contact Dana for further

investigation.

95
Troubleshooting

F0026 (Fault Reason 39)

Error Description Possible Causes Possible Solutions

BMS has detected an ESS internal 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.

96
Troubleshooting

F0026 (Fault Reason 40, 41, 42, 43)

Error Description Possible Causes Possible Solutions

BMS has detected a HV system 1) Defective charger 1) Replace charger

isolation fault.
2) HV system isolation fault 2) Contact Dana

This error indicates that the BMS has detected a HV Fault reason 43 indicates that the error occurred
system isolation fault. The BMS monitors voltage while in charging mode. In this case, the isolation
and current and raises an error if the calculated resistance threshold is 100 Ω/V. The charging
isolation resistance falls below a threshold. process will be terminated.

Fault reasons 40, 41, and 42 indicate that the error If the error occurred during charging and
occurred while in driving mode. These fault reasons subsequently disappears when using a different
are numbered in order of increasing severity: charger, it is likely that the error was caused by a
defective charger. The error should still be reported
to Dana.
Fault Reason Isolation Resistance
The VCU independently monitors isolation
40 ≤ 600 Ω/V (ohms per volt) resistance and will raise error F0035, F0036, F0037,
or F0038 if a loss of isolation is detected.
41 ≤ 500 Ω/V (ohms per volt)
In the event of a genuine loss of isolation, both a
42 ≤ 400 Ω/V (ohms per volt) BMS error (this error) and a VCU error (F0035,
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.
to 50%. If fault reason 41 is raised, driving will be
disabled. If fault reason 42 is raised, the BMS will
Warning: Loss of HV system isolation can
request the vehicle to shut down. In all cases, the
pose an extreme hazard and may result in
vehicle will not be able to restart until the error is
high voltage being present in parts of the
cleared.
vehicle that are not normally energized. Use
extreme caution and report all instances of
this error to Dana.

97
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 40/41/42/43

Has this error Yes Unplug EVSE and turn Key OFF
occurred while for 1 hour.
charging the Always report any instance of
vehicle? these faults to DANA.

Turn on ignition
Contact Dana for further
investigation.

Yes
Has the error been cleared?

Reconnect vehicle to EVSE and No

charge vehicle.

Contact Dana for further

investigation.

Complete
Possible error occurrence
Contact DANA about this problem

98
Troubleshooting

F0026 (Fault Reason 44)

Error Description Possible Causes Possible Solutions

BMS has detected a CAN 1) CAN communication problem. 1) Resolve CAN communication
communication problem. problem.

If this error is raised, the vehicle will only be able to

drive in limp mode and regenerative braking will be
disabled.

HMI displays or logs

Fault code F0026 and
BMS fault reason 44

Refer to the CAN investigation

subtree.
Investigate CAN A network.

Could you find a Yes 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.
Yes cycles?

Complete

99
Troubleshooting

F0026 (Fault Reason 45)

Error Description Possible Causes Possible Solutions

BMS has detected an ESS internal 1) ESS internal failure. 1) Contact Dana.
failure which requires support from
Dana.

If this error is raised, the vehicle will only be able to

drive in limp mode and regenerative braking will be
disabled. 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.

100
Troubleshooting

F0026 (Fault Reason 46)

Error Description Possible Causes Possible Solutions

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.

101
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.
defective HV connector or
MSD.

If this error is raised, the vehicle will only be able to

drive in limp mode and regenerative braking will be
disabled. Charging will be terminated. The vehicle
will not be able to restart until the error is cleared.

Connector C718 (yellow)

Connector C716 (black)

Connector C719 (orange)

Connector C717 (green)

MSD

102
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.

No
Are all HV connectors Relatch connecters and
latched? recheck for fault.

Yes

With a multimeter, check for continuity between the

following points:
MSD MSD
Connector pin Connector pin
HV 1 HV 2

LV 1 LV 2

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

103
Troubleshooting

Continued from previous page

Yes 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.

Yes
Was a defect found in the Defective harness.
high voltage connectors? Replace harness.

Contact Dana for further

investigation.

104
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.

The S-Box has its own internal HVIL which is

separate from the main vehicle HVIL. The S-Box
HVIL is a low voltage circuit passing through each
HV connector on the S-Box. If any of these
connectors is unplugged, the HVIL will be broken
and the BMS will raise fault reason 48.

If this error is raised, the vehicle will only be able to

drive in limp mode and regenerative braking will be
disabled. Charging will be terminated. The vehicle
will not be able to restart until the error is cleared.

Connector C718 (yellow)

Connector C716 (black)

Connector C719 (orange)

Connector C717 (green)

105
Troubleshooting

HMI displays or logs

Fault code F0026 and
BMS fault reason 48

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Disconnect connectors C718, C719,

C716 and C717 from the S-Box.

Refer to connector investigation

subtree.

Yes
Was a defect found in the Defective harness.
high voltage connectors? Replace harness.

Contact Dana for further

investigation.

106
Troubleshooting

F0026 (Fault Reason 49 to 70)

Error Description Possible Causes Possible Solutions

BMS has detected an ESS internal 1) ESS internal failure. 1) Contact Dana.
failure which requires support from
Dana.

If fault reason 50, 52, 54, 56, 58, 60, 62, 64, 66, 68,
or 70 is raised, the vehicle will only be able to drive
in limp mode and regenerative braking power will be
limited to 25%. If any of fault reasons 50 through 70
is raised during charging, charging will be
terminated.

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.

107
Troubleshooting

F0026 (Fault Reason 71)

Error Description Possible Causes Possible Solutions

BMS has detected an ESS internal 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.

108
Troubleshooting

F0026 (Fault Reason 73)

Error Description Possible Causes Possible Solutions

BMS has detected an abnormally 1) Inadequate or defective 1) Restart charging with a level 2
large discharge current during charger. charger.
charging.

If the error disappears when the vehicle is connected

to a level 2 charger, it is likely that the original
charger was inadequate or defective.

HMI displays or logs

Fault code F0026 and
BMS fault reason 73

Is a level 1 charger Yes

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 Yes

Contact Dana for further
raised on further charge
investigation.
cycles?

Complete

109
Troubleshooting

F0026 (Fault Reason 74)

Error Description Possible Causes Possible Solutions

BMS has detected an abnormally 1) Defective charger. 1) Restart charging with a level 2
large charging current. charger.

If the error disappears when the vehicle is connected

to a level 2 charger, the original charger maybe
defective.

HMI displays or logs

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 No

raised on further charge Complete
cycles?

Yes

Contact Dana for further

investigation.

110
Troubleshooting

F0026 (Fault Reason 75, 76, 77)

Error Description Possible Causes Possible Solutions

These faults are invalid in this 1) S-Box internal failure or 1) Contact Dana.
vehicle architecture. If they software error.
appear, please contact Dana for
further investigation.

Unplug EVSE from the truck if
batteries until the maximum cell
applicable.
voltage is less than 3.25V.

Wait one hour before taking Turn ignition OFF and switch
any further action. 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
No
message still
Complete
displayed on the
HMI?

Yes

Contact Dana for further

investigation.

114
Troubleshooting

F0026 (Fault Reason 102, 103, 104)

Error Description Possible Causes Possible Solutions

BMS has detected an ESS internal 1) ESS internal failure. 1) Contact Dana.
failure which requires support from
Dana.

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.

115
Troubleshooting

F0027 - High Voltage System Fault

Error Description Possible Causes Possible Solutions

BMS has requested driving to be 1) ESS fault. 1) Troubleshoot specific error.

disabled due to an ESS fault.

This error is expected to be accompanied by error If error F0027 appears without one of the listed
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.

HMI displays or logs

Fault code F0027

Yes
Is F0026 BMS 5/12/15/41 Refer to the corresponding error
also present? troubleshooting tree.

Contact Dana for further

investigation.

116
Troubleshooting

F0028 - High Voltage System Fault

Error Description Possible Causes Possible Solutions

BMS derates the high voltage 1) ESS fault. 1) Troubleshoot specific error.
power, limited to 50% due to an
ESS fault.

This error is expected to be accompanied by error If error F0028 appears without one of the listed
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.

HMI displays or logs

Fault code F0028

Is F0026 BMS 4/11/ Yes

Refer to the corresponding error
14/22/23/24/32/33/34/40
troubleshooting tree.
also present?

Contact Dana for further

investigation.

117
Troubleshooting

F0029 - High Voltage System Fault

Error Description Possible Causes Possible Solutions

BMS has requested the vehicle to 1) ESS fault. 1) Troubleshoot specific error.
shut down due to an ESS fault.

This error is expected to be accompanied by error If error F0029 appears without one of the listed
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 vehicle to shut
down in response to fault reason 6, 7, 13, 29, 37, or
42.

HMI displays or logs

Fault code F0029

Is F0026 Yes
Refer to the corresponding error
BMS 6/7/13/29/37/42
troubleshooting tree.
also present?

Contact Dana for further

investigation.

118
Troubleshooting

F0030 - High Voltage System Fault

Error Description Possible Causes Possible Solutions

BMS has requested the vehicle to 1) ESS fault. 1) Troubleshoot specific error.
shut down due to an ESS fault.

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.
requested. The BMS will request the vehicle to shut
down in response to fault reason 16.

HMI displays or logs

Fault code F0030

Yes
Is F0026 BMS 16 Refer to error F0026 BMS 16
also present? troubleshooting tree.

Contact Dana for further

investigation.

119
Troubleshooting

F0032 - Regenerative Braking reduced

Error Description Possible Causes Possible Solutions

BMS has requested regenerative 1) ESS fault. 1) Troubleshoot specific error.

braking to be disabled due to an
ESS fault.

This error is expected to be accompanied by error If error F0032 appears without one of the listed
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.

HMI displays or logs

Fault code F0032

Is F0026 BMS 1/2/3/7/9/ Yes

10/15/16/26/27/28/29/37/ Refer to the corresponding error
41/42/44/45/47/48/103/104 troubleshooting tree.
also present?

Contact Dana for further

investigation.

120
Troubleshooting

F0033 - Regenerative Braking reduced

Error Description Possible Causes Possible Solutions

BMS has requested the 1) ESS fault. 1) Troubleshoot specific error.

regenerative braking power to be
limited to 25% due to an ESS fault.

This error is expected to be accompanied by error If error F0033 appears without one of the listed
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.

HMI displays or logs

Fault code F0033

Fault code F0038

Yes
Is F0026 BMS 43 Refer to error F0026 BMS 43
also present? troubleshooting tree.

Contact Dana for further

investigation.

126
Troubleshooting

F0039 - Charging system limited

Error Description Possible Causes Possible Solutions

BMS has limited the charging rate 1) ESS fault. 1) Troubleshoot specific error.
to 50% due to overheating in the
ESS.

This error may be accompanied by one or more of

errors F0019, F0020, F0045, or F0119, indicating a
specific problem with the ESS cooling system. The
technician should troubleshoot the specific error.

HMI displays or logs

Fault code F0039

Is F0019, F0020 or Yes Refer to corresponding error

F0045 also present? troubleshooting tree.

Is F0119 also Yes 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 Yes Contact Dana for further

raised on further charge
investigation.
cycles?

Complete

127
Troubleshooting

F0040 - Charging rate was reduced due to fault

Error Description Possible Causes Possible Solutions

BMS has limited the charging rate 1) ESS fault. 1) Troubleshoot specific error.
due to an ESS fault.

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.
requested. The BMS will limit the charging rate in
response to fault reason 47.

HMI displays or logs

Fault code F0040

Yes
Is F0026 BMS 47 Refer to error F0026 BMS 47
also present? troubleshooting tree.

Contact Dana for further

investigation.

128
Troubleshooting

F0041 - Powertrain charging system fault

Error Description Possible Causes Possible Solutions

BMS has terminated the charging 1) ESS fault. 1) Troubleshoot specific error.
process and opened the charging
relay due to an ESS fault.

This error is expected to be accompanied by error If error F0041 appears without one of the listed
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.

HMI displays or logs

Fault code F0041

Yes
Is F0026 BMS 7/37 Refer to the corresponding error
also present? troubleshooting tree.

Contact Dana for further

investigation.

129
Troubleshooting

F0042 - Powertrain charging system fault

Error Description Possible Causes Possible Solutions

BMS has terminated the charging 1) ESS fault. 1) Troubleshoot specific error.
process due to an ESS fault

This error is expected to be accompanied by error If error F0042 appears without one of the listed
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,
15, 16, 28, 29, 43, 45, 46, 48, 55, 56, 57, 58, 59, 60,
61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 73, 74, 75,
or 77.

HMI displays or logs

Fault code F0042

Is F0026 BMS 1/2/3/8/9/

10/15/16/28/29/43/45/48/55/ Yes
Refer to the corresponding error
56/57/58/59/60/61/62/63/64/65/
troubleshooting tree.
66/67/68/69/70/71/73/74/75/77
also present?

Contact Dana for further

investigation.

130
Troubleshooting

F0043 - High Voltage System Fault. Vehicle restart will be prohibited

Error Description Possible Causes Possible Solutions

Vehicle is prohibited from starting 1) ESS fault. 1) Troubleshoot specific error.

due to an ESS fault.

If the vehicle is already powered on, it will not be 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. The BMS will prohibit the vehicle from
starting in response to fault reason 28, 29, 37, 38,
39, 40, 41, 42, 45, 47, or 48.

HMI displays or logs

Fault code F0043

Is F0026 BMS 28/29/ Yes

37/38/39/40/41/42/45/47/ Refer to the corresponding error
48 or F0035/F0036/F0037 troubleshooting tree.
also present?

Contact Dana for further

investigation.

131
Troubleshooting

F0044 - High Voltage System Fault

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.

If the vehicle does not shut down within 35 seconds, This error is expected to be accompanied by error
relays will be opened to immediately isolate the ESS. F0026 which provides a BMS fault reason code
indicating the specific reason the limitation was
The vehicle will not be able to start again after requested. The BMS will prohibit the vehicle from
shutdown. starting and will request a shutdown in response to
fault reason 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

Yes
Is F0026 BMS 7 Refer to error F0026 BMS 7
also present? troubleshooting tree.

Contact Dana for further

investigation.

132
Troubleshooting

F0045 - Energy Storage Cooling System Fault

Error Description Possible Causes Possible Solutions

BMS has requested the ESS 1) ESS fault. 1) Troubleshoot specific error.
cooling system to shut off due to
an ESS fault. 2) ESS cooling system problem. 2) Resolve ESS cooling system
problem.

This error is expected to be accompanied by error If error F0045 appears without one of the listed
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.

HMI displays or logs

Fault code F0045

Wait for the cooling liquid to cool down and

check the chiller tank liquid level Complete

Yes
Is the chiller tank liquid Refill coolant and cycle the truck Is the error still being
level low? ignition. raised?

No Yes

Are there other Fault Yes Refer to the corresponding error

Codes raised at this same
troubleshooting tree.
time?

Continued on next page

133
Troubleshooting

No
Continued from previous page

Does the HMI also Yes Refer to the TMS No contact

display “TMS No
troubleshooting tree.
contact”?

No
Dismount the ESS dust cover to inspect the
cooling piping for possible leaks, clogging or
flow reduction. Refer to the maintenance
manual to access the piping.

Repair the defect as per the Yes Is there any evidence

maintenance manual of a defect causing a
instructions. cooling reduction ?

Inspect the rest of the ESS cooling

circuit for leaks, clogs or possible
flow reduction.

Fault code F0049

Yes
Is F0026 BMS 4/5/6 Refer to the corresponding error
also present? troubleshooting tree.

Contact Dana for further

investigation.

138
Troubleshooting

F0107 - Battery Thermal Management Fault

Error Description Possible Causes Possible Solutions

BMS has reported a thermal 1) ESS fault. 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

Fault code F0107

Is F0019, F0020, Yes

Refer to the corresponding error
F0026 BMS 35 or
troubleshooting tree.
F0045 also present?

Contact Dana for further

investigation.

139
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.
2) Loss of continuity between
chiller and coolant level sensor 2) Replace LV connector or
due to defective LV connector harness per Service Manual.
or harness.
3) Replace coolant level sensor.
3) Defective coolant level sensor.

Connector C40

Connector C39

Connector C46

140
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

No
Is the chiller tank liquid
level low ? A

Yes

Check the chiller tank for

potential leaks

Yes Replace the cooling tank

Is there any leaks in the
following the maintenance
cooling tank ?
manual instructions.

Yes Replace the faulty cooling

Is there any leaks in the pipes following the
ESS cooling circuit ? maintenance manual
instructions.

There is probably a leak in

the ESS piping ? Check with
PACCAR how we could
troubleshoot this

141
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
Yes
Service Chart” in the Service Manual integrity?

With a multimeter, check for continuity between the

following points:

C40 Tank C39

Connector pin Connector pin
Pin 35 Pin 1

Pin 36 Pin 2

C40 Chiller C46

Connector pin Connector pin

Pin 35 Pin 1

Pin 36 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

Defective harness. Yes Is there any evidence of

Replace harness. a continuity loss ?

Defective level sensor.

Replace level sensor.

142
Troubleshooting

F0129 - Battery SOC Imbalance. Please charge battery to 100%

Error Description Possible Causes Possible Solutions

BMS has reported an imbalance in 1) ESS fault. 1) Troubleshoot specific error.

the state of charge (SOC) between
the ESS battery packs.

This error is expected to be accompanied by F0026 Note: If requested during this procedure to
(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,

10, 11, 12, 13) may also be raised at the same time.

143
Troubleshooting

HMI displays or logs

Fault code F0129

Yes
Is F0026 BMS 1/2/3/4/5/6 Refer to the specific error
also present? troubleshooting tree.

Turn on heater to discharge HV

Unplug EVSE from the truck if
batteries until the maximum cell
applicable.
voltage is less than 3.25V.

Wait one hour before taking Turn ignition OFF and switch
any further action. 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.

No
Is the fault code
Complete
still present?

Yes

Contact Dana for further

investigation.

144
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.
harness.
3) Replace Battery TMS.
3) Battery TMS internal 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 TMS monitors
continuity between the HVIL pins on its HV
connector (C724). If this connector is unplugged
unsafely, the HVIL will be broken and the TMS will
send an error message via CAN.

Connector C724

145
Troubleshooting

HMI displays or logs

Fault code F0146

Yes
Is F0019 or F0020 Refer to corresponding error
also present? troubleshooting tree.

Disconnect connector C724 from chiller.

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
Refer to connector investigation
and Diagnostic Guide.
subtree.

Is there any
Yes
problem with the Defective connector.
connector Replace harness.
integrity?

With a multimeter, check for continuity between the

following points:

Cradle C724S Tank C724S

Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to 2ohms.

No Yes
Contact Dana for further Is there any evidence of Defective harness.
investigation. a continuity loss ? Replace harness.

146
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). 100%. Always fully change the vehicle until
the charge cycle automatically ends. Only
Note: If requested during this procedure to charge vehicle using a level 2 or level 3
connect the vehicle to a charger, a level 2 EVSE.
charger is required.
Note: Make sure HV systems are not in use
Note: For best ESS performance and while charging.
vehicle range HV batteries must regularly be
changed to 100% SOC. Vehicle SOC is a
calculated valued that drifts over time. It is
recalibrated only at the end of the charge

HMI displays or logs

Fault code F0153

Is F0026 Yes
Refer to the corresponding error
BMS 1/2/3/4/5/6
troubleshooting tree.
also present?

Plug in only a level 2 AC charger.

Charge vehicle until charge cycle
automatically ends.

147
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. It is
the cell voltage. If the reported SOC is implausibly recalibrated only at the end of the charge
low based on the cell voltage, the VCU will raise cycle when HV batteries are charged to
error F0154. 100%. Always fully change the vehicle until
the charge cycle automatically ends. Only
Note: If requested during this procedure to charge vehicle using a level 2 or level 3
connect the vehicle to a charger, a level 2 EVSE.
charger is required.
Note: Make sure HV systems are not in use
Note: For best ESS performance and while charging.
vehicle range HV batteries must regularly be
changed to 100% SOC. Vehicle SOC is a

HMI displays or logs

Fault code F0154

Plug in only a level 2 AC charger.

Charge vehicle until charge cycle
automatically ends.

148
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.

The VCU compares the SOC reported by the BMS to calculated valued that drifts over time. It is
the cell voltage. If the reported SOC is implausibly recalibrated only at the end of the charge
high based on the cell voltage, the VCU will raise cycle when HV batteries are charged to
error F0155. 100%. Always fully change the vehicle until
the charge cycle automatically ends. Only
Note: If requested during this procedure to charge vehicle using a level 2 or level 3
connect the vehicle to a charger, a level 2 EVSE.
charger is required.
Note: Make sure HV systems are not in use
Note: For best ESS performance and while charging.
vehicle range HV batteries must regularly be
changed to 100% SOC. Vehicle SOC is a

HMI displays or logs

Fault code F0155

Plug in only a level 2 AC charger.

Charge vehicle until charge cycle
automatically ends.

149
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. 2) Replace 12V fuse F19.

3) Defective relay K004, K005, 3) Replace defective relay.

K006, or K007.
4) Replace LV connector or
4) Loss of continuity caused by harness per Service Manual.
defective LV harness or
connector. 5) Repair or replace cut loop
wiring.
5) Cut loop broken or faulty cut
loop wiring. 6) Resolve CAN communication
problem.
6) CAN communication problem.
7) Troubleshoot specific error.
7) Loss of power to MPDM or
MPDM internal failure. 8) Replace VCU.

8) VCU internal 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.

Connector C40
Connector C11 (black)

150
Troubleshooting

Connector C44

Connector C54

Connector C50

Connector C75

Connector C53 Connector C76

151
Troubleshooting

Connector C93P (pin) Connector C367P (pin)

Connector C93S (socket)

Connector C367S (socket)

Connector C100

152
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 Yes Take the actions Is the error code still
problem in the CAN A or C
prescribed in the subtree. displayed?
network?

No Yes

Does the HMI also Yes

Refer to the MPDM No contact
display “MPDM No
troubleshooting tree.
contact”?

Does the HMI also Yes

Refer to the Traction inverter No
display “Traction inverter
contact troubleshooting tree.
No contact”?

Yes
Does the HMI also Refer to error F0058 troubleshooting
display F0058? tree.

No Continued on next page

153
Troubleshooting

No Continued from previous page

Yes
Does the HMI also display Refer to error F0064 troubleshooting
F0064? tree.

Yes
Does the HMI also display Refer to error F0069 troubleshooting
F0069? tree.

Yes
Does the HMI also display Refer to error F0071 troubleshooting
F0071? tree.

Yes
Does the HMI also display Refer to error F0080 troubleshooting
F0080? tree.

Yes
Does the HMI also display Refer to error F0084 troubleshooting
F0084? tree.

No Continued on next page

154
Troubleshooting

No Continued from previous page

Does the HMI Yes

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.

Yes
Is fuse F19 blown
or intermittent? A
No

Disconnect connector C11 from MPDM.

Disconnect connector C93.
Disconnect connector C75.
Disconnect connector C76.
Disconnect connector C367.
Disconnect connector C40.
Disconnect connector C50.
Disconnect connector C53 and C54 from CCU.
Remove fuse F19 in order to take continuity
measures from inside the fuse box.

Refer to connector investigation

subtree.

Continued on next page

155
Troubleshooting

Continued from previous page

Defective connector.
Is there any problem with Yes 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
Connector pin Connector pin
Pin A Pin 7

Pin D Pin 5
MPDM C11 C40S
Connector pin Connector pin
Pin G Pin 12

C93S C75
Connector pin Connector pin
Pin 7 Pin 1

Pin 8 Pin 4

C93S C76
Connector pin Connector pin
Pin 5 Pin 1

Pin 6 Pin 4

C93P C40S
Connector pin Connector pin
Pin 8 Pin 11

Pin 6 Pin 9

C40P C367S
Connector pin Connector pin
Pin 11 Pin 8

Pin 9 Pin 11

Pin 12 Pin 12
C44 S-Box C367S
Connector pin Connector pin
Pin 1 Pin 8

Pin 2 Pin 8

Pin 14 Pin 12

Pin 13 Pin 11

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

156
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 Connector pin
Pin 6 Pin 7

C76 C40S
Connector pin Connector pin
Pin 2 Pin 30

C76 C40S
Connector pin Connector pin
Pin 2 Pin 31

C40P C50S
Connector pin Connector pin
Pin 30 Pin N

Pin 31 Pin O

C50P C50S
Connector pin Connector pin
Pin N Pin H1

C50P C50S
Connector pin Connector pin
Pin O Pin F2

12V fuse box C14 C75

Terminal Connector pin
C9 Pin 3

12V fuse box C14 C76

Terminal Connector pin
C9 Pin 3

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

157
Troubleshooting

Continued from previous page

Yes
Is there any evidence Defective harness.
of a continuity loss? Replace harness.

Refer to relay investigation

subtree.
Relay Investigation
Investigate relay K004, K005, K007,
K006.

Is there any evidence of a Yes

Defective relay.
defect between the pins of
Replace relay.
the relay?

Defective supervisory controller.

Replace supervisory controller.

Is the error still Yes

occurring on further Contact Dana for further
key ON or charge investigation.
cycles?

Complete

158
Troubleshooting

Disconnect blown fuse F19 from

12V fuse box C14.

Replace fuse F19 from 12V fuse

box C14.
Restart the vehicle.

Did fuse F19 No

blow again during Complete
test drive?

Yes

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Turn ignition OFF and

disconnect F19 from 12V fuse
box C14.

Refer to relay investigation

subtree.
Investigate relay K004, K005, K007,
K006.

Is there
any evidence Yes
Defective relay.
of a defect between
Replace relay.
the pins of the
relay?

Continued on next page No

159
Troubleshooting

Continued from previous page

Refer to connector investigation subtree.

No
With a multimeter, check for short circuit between the
following points:

12V fuse box C14 C9 Ground

Terminal
C9 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Is there any evidence No Defective harness.

of a short circuit within
Replace harness.
the harness?

Yes

Replace fuse F19 from 12V fuse

box C14.
Restart the vehicle.

Did fuse F19 blow again No

Complete
during test drive?

Yes

Contact Dana for further

investigation. 160
Troubleshooting

Charging System

The charging system converts electrical energy input Charge Inlet

to charge the ESS. It can accept either alternating
current (AC) or direct current (DC) input. The vehicle The charge inlet is the socket to which the external
is charged using a charger that is attached to the electrical supply (AC or DC) is connected. When
electrical power grid. The charger is referred to in enabled by the charge controller, it supplies power to
this manual as an EVSE (Electric Vehicle Supply the OBC.
Equipment).
Note: There are different levels of external
high voltage changers (EVSE) used to
Component descriptions change the high voltage system. Vehicles
with Dana BEV system must use level 2 or
OBC level 3 chargers for proper changing of the
HV batteries.
The onboard charger (OBC) receives AC or DC input
from the charge inlet and converts it to 650V DC Note: When recharging the HV batteries
output to charge the ESS. It is powered by 12V low must regularly be charged to 100% for
voltage from the MPDM and communicates via the proper cell balancing and SOC calibration.
CAN B network. This maintains the vehicle’s designed range
and extends the life of the HV batteries.
Charge controller

The charge controller manages the charging

process. It is powered by 12V low voltage from the
MPDM and communicates via the CAN A network.

161
Troubleshooting

F0003 - Error occurred while charging: Please check charge level before driving.

Error Description Possible Causes Possible Solutions

Charging was aborted due to an 1) Charge controller, OBC, or 1) Troubleshoot specific error.
error. ESS fault.

Charging may be aborted in response to specific errors in the charge controller (F0005, F0006, or F0007), OBC
(F0088), or ESS (F0026). Other VCU errors related to charging (F0004 or F0131) may also appear.

HMI displays or logs

Fault code F0003

Does the HMI also display Yes

Refer to the corresponding error
F0004, F0005, F0006, F0007,
troubleshooting tree.
F0026, F0131, or F0088?

Has F0003 appeared in the Yes

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
No fault log?

Yes

Contact Dana for further

investigation.

162
Troubleshooting

F0004 - High Voltage System fault

Error Description Possible Causes Possible Solutions

VCU has detected that the HV 1) ESS fault. 1) Troubleshoot specific error.
system has failed to pass the
precharge stage.

The precharge circuit manages the voltage ramp-up precharge as failed and the vehicle startup will be
of the HV system upon startup of the vehicle. aborted.
Precharge ends when the voltage of the HV
distribution system reaches 95% of the ESS voltage. If precharge has failed, Error F0017 or F0018 is also
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.

HMI displays or logs

Fault code F0004

Is F0017 or Yes Refer to the corresponding error

F0018 also
troubleshooting tree.
present?

Contact Dana for further

investigation.

163
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. EVSE.

This error is expected to be accompanied by error

F0042. If this is the case, the technician should Note: When requested to connect the
troubleshoot error F0042. vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.
If error F0042 has not been raised, it may be
possible to resolve the error by restarting the charge
using a compatible EVSE.

164
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 1
Fault code F0006 and Charge end reason 1
Fault code F0007 and Charge end reason 1

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0042 been Yes

Refer to the F0042
raised previously during
troubleshooting tree.
this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

165
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. EVSE.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

166
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 2
Fault code F0006 and Charge end reason 2
Fault code F0007 and Charge end reason 2

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has a “BMS No Yes

contact” been raised Refer to the BMS No contact
previously during this troubleshooting tree.
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
167
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.

3) Incompatible or defective 3) Restart charge with compatible

EVSE. EVSE.

This message is not displayed to the driver but may If error F0154 or F0155 is raised, the SOC
still appear in the HMI fault log. If charge controller measurement may not be accurate. In this case, the
Charge end reason 3 appears without any other technician should troubleshoot error F0154 or
errors and the SOC is at 100% then the charging F0155.
system is operating correctly, and no troubleshooting
is needed. Note: When requested to connect the
vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

168
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 3
Fault code F0006 and Charge end reason 3
Fault code F0007 and Charge end reason 3

Unplug charger and put the

Access the fault log on the HMI.
vehicle in accessory mode.

Has the message been

raised after the vehicle has No Has error F0026, F0154, or Yes
Refer to the corresponding
been charged and the SOC has F0155 been raised previously
error troubleshooting tree.
reached 100% on the during this charge?
High Voltage battery?

Yes
No
Complete Turn ignition OFF and unplug the
EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Is the vehicle able to

Yes
charge completely to Reconnect a compatible EVSE to
Complete
100% without raising the start charge.
same fault?

Contact Dana for further

investigation.

169
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. EVSE.

The error is expected to be accompanied by a BMS Note: When requested to connect the
error (F0026) that triggered the fault. If F0026 is not vehicle to an EVSE, either a level 2 or level
raised, it may be possible to resolve the error by 3 EVSE can be used.
restarting the charge with a compatible EVSE.

170
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 4
Fault code F0006 and Charge end reason 4
Fault code F0007 and Charge end reason 4

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0026 been Yes

raised on the HMI during Refer to the F0026
charge prior to this error troubleshooting tree.
being raised?

Turn the vehicle OFF and unplug

the 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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

171
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. EVSE.

If no other error has been raised, it may be possible Note: When requested to connect the
to resolve the error by restarting the charge using a vehicle to an EVSE, either a level 2 or level
compatible EVSE. 3 EVSE can be used.

172
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 5
Fault code F0006 and Charge end reason 5
Fault code F0007 and Charge end reason 5

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has any other error Yes

been raised previous to Refer to the corresponding error
this one during the last troubleshooting tree.
charge cycle?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

173
Troubleshooting

F0005, F0006, F0007 (Charge end reason 6)

Error Description Possible Causes Possible Solutions

VCU has reported that the high 1) Incompatible or defective 1) Restart charge with compatible
voltage system is offline. EVSE. EVSE.

It may be possible to resolve the error by restarting Note: When requested to connect the
the charge using a compatible EVSE. vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

HMI displays or logs

Fault code F0005 and Charge end reason 6
Fault code F0006 and Charge end reason 6
Fault code F0007 and Charge end reason 6

Turn ignition OFF and unplug the

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 Yes

charge completely to 100%
Complete
without raising the same
fault?

Yes

Contact Dana for further

investigation.

174
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. EVSE.

The error is expected to be accompanied by one or

more ESS errors (F0026, F0047, or F0049) that Note: When requested to connect the
triggered the fault. If no BMS error is raised, it may vehicle to an EVSE, either a level 2 or level
be possible to resolve the error by restarting the 3 EVSE can be used.
charge with a compatible EVSE.

175
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 7
Fault code F0006 and Charge end reason 7
Fault code F0007 and Charge end reason 7

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0026, F0049, Yes

F0047, F0154, or F0155 been Refer to the corresponding
raised previously during this error troubleshooting tree.
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
176
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.

The error is expected to be accompanied by one or

more ESS errors (F0026 or F0048) that triggered the Note: When requested to connect the
fault. If no BMS error is raised, it may be possible to vehicle to an EVSE, either a level 2 or level
resolve the error by restarting the charge with a 3 EVSE can be used.
compatible EVSE.

177
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 8
Fault code F0006 and Charge end reason 8
Fault code F0007 and Charge end reason 8

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0048 or Yes

F0026 been raised Refer to the corresponding error
previously during this troubleshooting tree.
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
178
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. EVSE.

The error is expected to be accompanied by one or

more of F0026 and F0092. If neither of these errors Note: When requested to connect the
is raised, it may be possible to resolve the error by vehicle to an EVSE, either a level 2 or level
restarting the charge with a compatible EVSE. 3 EVSE can be used.

179
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 9
Fault code F0006 and Charge end reason 9
Fault code F0007 and Charge end reason 9

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0026 or Yes

F0092 been raised Refer to the corresponding error
previously during this troubleshooting tree.
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
180
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. EVSE. EVSE.

The error is expected to be accompanied by one or

more Supervisory controller error messages (F0051 Note: When requested to connect the
or F0052). If neither of these errors is raised, it may vehicle to an EVSE, either a level 2 or level
be possible to resolve the error by restarting the 3 EVSE can be used.
charge with a compatible EVSE.

181
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 10
Fault code F0006 and Charge end reason 10
Fault code F0007 and Charge end reason 10

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0051 or Yes

F0052 been raised Refer to the corresponding error
previously during this troubleshooting tree.
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
182
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. EVSE.

The purpose of the HVIL is to provide a warning if This error is expected to be accompanied by the
any HV connector is unplugged without the HV specific HVIL error (F0026, F0061, F0062, F0063,
distribution being safely ended. The charge F0139, F0140, F0142, F0143, F0144, or F0146) that
controller will raise this fault code if any HVIL error triggered the fault. If none of these errors is raised, it
occurs during charging. may be possible to resolve the error by restarting the
charge with a compatible EVSE.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

183
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 11
Fault code F0006 and Charge end reason 11
Fault code F0007 and Charge end reason 11

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0026,

F0061, F0062, F0063, F0139, Yes
Refer to the corresponding error
F0140, F0143, F0142, F0144, or
troubleshooting tree.
F0146 been raised previously
during this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
184
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.
2) Incompatible or defective 2) Restart charge with compatible
EVSE. EVSE.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

185
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 12
Fault code F0006 and Charge end reason 12
Fault code F0007 and Charge end reason 12

Unplug charger.

If possible, connect another compatible

EVSE to the vehicle and restart charge. If no
other EVSE is available, unplug the faulty
EVSE from the grid and let it reinitialize
before restarting charge.

Is the vehicle able to Yes

charge completely to
Complete
100% without raising the
same fault?

Investigate the shop power

for operation interruptions
during charge.

Could you find any Yes

defect with shop Complete
power supply?

Contact Dana for further

investigation.

186
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. EVSE.

The cut loop is a section of LV wiring which can be possibly F0108 or F0147 are expected to be raised.
cut by first responders to shut down the HV system The technician should begin by troubleshooting error
in an emergency. F0058, F0108, or F0147 if one of these appears.

If the cut loop is broken: If none of errors F0058, F0108, or F0147 is raised, it
may be possible to resolve the error by restarting the
• Contactors inside the S-Box will open to charge with a compatible EVSE.
isolate the high voltage battery packs from
the HV distribution system. If the vehicle is Note: If a cut loop problem is indicated,
stopped, this occurs immediately. If the check for errors F0058, F0108, or F0147
vehicle is moving, it will occur as soon as the before troubleshooting any other possible
vehicle speed drops below 5 km/h. root cause.
• The VCU will notify the driver immediately by
raising error F0058 and will prohibit Note: When requested to connect the
restarting the vehicle. vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.
If the cut loop is broken, various other errors
including F0016, F0058, BMS no contact, and

187
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 13
Fault code F0006 and Charge end reason 13
Fault code F0007 and Charge end reason 13

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0058, F0108 or Yes

Refer to the corresponding error
F0147 been raised previously
troubleshooting tree.
during or before this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

188
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. EVSE.

The error is expected to be accompanied by the Note: When requested to connect the
VCU error (F0095) that triggered the fault. If F0095 vehicle to an EVSE, either a level 2 or level
is not raised, it may be possible to resolve the error 3 EVSE can be used.
by restarting the charge with a compatible EVSE.

189
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 14
Fault code F0006 and Charge end reason 14
Fault code F0007 and Charge end reason 14

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0095 been Yes

Refer to the F0095
raised previously during or
troubleshooting tree.
before this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
190
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. EVSE.

3) Loss of continuity between 3) Replace LV connector or

charge controller and charge harness per Service Manual.
inlet due to defective LV
connector or harness.

Warning: High voltage hazard. The harness

between the charge controller and charge
inlet is a low voltage harness. However, in
the event of a specific charging system
malfunction, it is possible that the harness
could be exposed to high voltage. Treat it as
a high voltage harness.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

Connector C102P (pin)

Connector C52

191
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 Yes

raised after the EVSE has been
Complete
normally unplugged from the
vehicle?

Unplug EVSE.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

If this is the first time you are

restarting charge, try to use the
same EVSE, if the errors comes
up repeatedly then try to restart
the charge with a different
compatible EVSE.

Is the vehicle able to Yes

charge completely to
Complete
100% without sending
any fault?

Continued on next page No

192
Troubleshooting

No Continued from previous page

Disconnect connector C102 from

charge inlet.
Disconnect connector C52 from
WARNING: Electrical hazard.
the CCU.
Follow Safety Warnings and High
Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide. Refer to the connector
investigation subtree.

No
Is there any problem with
the connector integrity?
Yes

With a multimeter, check for continuity between the

following points:
CCU C52 C102 Charge inlet
Connector pin Connector pin Defective connector.
Replace the connector as described in the “Wire
Pin E1 Pin 2
Harness Connector Identification, Location, and
Pin F1 Pin 1 Service Chart” in the Service Manual

- Continuity : Resistance is less than or equal to 2ohms.

Is there any evidence Yes

Defective harness.
of a continuity loss in
Replace harness.
the harness?

Contact Dana for further

investigation.

193
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.

3) Incompatible or defective 3) Restart charge with compatible

EVSE. EVSE.

This message is not displayed to the driver but may If error F0153, F0154, or F0155 is raised, the SOC
still appear in the HMI fault log. If charge controller measurement may not be accurate. The technician
Charge end reason 16 appears without any other should troubleshoot F0153, F0154, or F0155 first.
errors and the SOC is at 100% then the charging
system is operating correctly, and no troubleshooting Note: When requested to connect the
is needed. vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.
It may be possible to resolve the error by restarting
the charge with a compatible EVSE.

194
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 16
Fault code F0006 and Charge end reason 16
Fault code F0007 and Charge end reason 16

Unplug charger and put the

Access the fault log on the HMI.
vehicle in accessory mode.

No Has error F0153, F0154 or Yes

Refer to the corresponding
F0155 been raised previously
error troubleshooting tree.
during or before this charge?

Has the message been

raised after the vehicle has No
Turn ignition OFF and unplug the
been charged and the SOC has
EVSE if applicable.
reached 100% on the
High Voltage battery?

Wait for vehicle shutdown and

wait 2 minutes after shutdown.
Yes
Is the vehicle able to
Yes
charge completely to Reconnect a compatible EVSE to
Complete
100% without raising the start charge.
same fault?

Contact Dana for further

investigation.

195
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. EVSE.

The purpose of the HVIL is to provide a warning if This error is expected to be accompanied by the
any HV connector is unplugged without the HV OBC error (F0088) that triggered the fault. If no HVIL
distribution being safely ended. The charge error is raised, it may be possible to resolve the error
controller will raise this fault code if an HVIL error by restarting the charge with a compatible EVSE.
occurs in the OBC.
Note: When requested to connect the
vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

196
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” or Yes
Refer to the corresponding error
F0088 been raised
troubleshooting tree.
previously, during or before
this charge?

Turn ignition OFF and unplug the

EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Reconnect a compatible EVSE to

start charge.

Continued on next page

197
Troubleshooting

Continued from previous page

Is the vehicle able to Yes

charge completely to
Complete
100% without raising the
same fault?

Has error F0061/F0062/F0088 Yes

Refer to the corresponding error
0x3302 been raised previously
troubleshooting tree.
during or before this charge?

Contact Dana for further

investigation.

198
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. EVSE.

The error is expected to be accompanied by the Note: When requested to connect the
OBC error (F0088) that triggered the fault. If error vehicle to an EVSE, either a level 2 or level
F0088 is not raised, it may be possible to resolve the 3 EVSE can be used.
error by restarting the charge with a compatible
EVSE.

199
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 Yes

contact” or F0088 been Refer to the corresponding error
raised previously during or troubleshooting tree.
before this charge?

Turn ignition OFF and unplug the

EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Reconnect a compatible EVSE to

start charge.

Continued on next page

200
Troubleshooting

Continued from previous page

Is the vehicle able to Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

201
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.

202
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 Yes

contact” or F0088 been Refer to the corresponding error
raised previously during or troubleshooting tree.
before this charge?

Turn ignition OFF and unplug the

EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Reconnect a compatible EVSE to

start charge.

Continued on next page

203
Troubleshooting

Continued from previous page

Is the vehicle able to Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

204
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.

205
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 Yes

contact” or F0088 been Refer to the corresponding error
raised previously during or troubleshooting tree.
before this charge?

Turn ignition OFF and unplug the

EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Reconnect a compatible EVSE to

start charge.

Continued on next page

206
Troubleshooting

Continued from previous page

Is the vehicle able to Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

207
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 vehicle to an EVSE, either a level 2 or level
charging and the cell imbalance could not be 3 EVSE can be used.
resolved within a 3-hour time limit.
Note: For best ESS performance and
Cell voltage is also monitored by the BMS and the vehicle range HV batteries must regularly be
VCU, which will raise their own errors (F0026 and changed to 100% SOC. Vehicle SOC is a
F0153, respectively) if an imbalance is detected. If calculated valued that drifts over time. It is
charge controller fault reason 21 appears without recalibrated only at the end of the charge
either of these errors, it may be possible to resolve cycle when HV batteries are charged to
the error by restarting the charge with a compatible 100%. Always fully change the vehicle until
EVSE. the charge cycle automatically ends. Only
charge vehicle using a level 2 or level 3
EVSE.

208
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.

Yes Drive the truck for a few minutes

Has the High Voltage battery
in order to discharge the High
SOC reached 100%?
Voltage battery a little.

No A
Unplug charger and put the
vehicle in accessory mode.

Access the fault log on the HMI.

Continued on next page

209
Troubleshooting

Continued from previous page

Has error F0026/F0153 Yes

been raised previously Refer to the corresponding error
during or before this troubleshooting tree.
charge?

A Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

210
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.

This message is not displayed to the driver but may Note: When requested to connect the
still appear in the HMI fault log. If charge controller vehicle to an EVSE, either a level 2 or level
fault reason 22 appears without any other errors and 3 EVSE can be used.
the SOC is at 100% then the charging system is
operating correctly, and no troubleshooting is
needed. Otherwise, it may be possible to resolve the
error by restarting the charge with a compatible
EVSE.

211
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 22
Fault code F0006 and Charge end reason 22
Fault code F0007 and Charge end reason 22

Has the message been

raised after the vehicle has Yes
been charged and the SOC has Complete
reached 100% on both
High Voltage batteries?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

212
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. EVSE.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

213
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 23
Fault code F0006 and Charge end reason 23
Fault code F0007 and Charge end reason 23

Turn OFF cabin heater and air

conditioning if applicable.

No
Is the error still being
Complete
raised during charge?

Yes

Turn the vehicle OFF and unplug

the 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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
214
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.

This error is expected to be accompanied by error Note: When requested to connect the
F0041. If this is the case, the technician should vehicle to an EVSE, either a level 2 or level
troubleshoot error F0041. 3 EVSE can be used.

If error F0041 has not been raised, it may be

possible to resolve the error by restarting the charge
using a compatible EVSE.

215
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 24
Fault code F0006 and Charge end reason 24
Fault code F0007 and Charge end reason 24

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0041 been raised Yes

Refer to the F0041
previously during or before
troubleshooting tree.
this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
216
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.

The charge controller has reported that the BMS has This error is expected to be accompanied by error
prohibited the vehicle from starting and has F0044. If this is the case, the technician should
requested the vehicle to shut down. If the vehicle troubleshoot error F0044.
does not shut down within 35 seconds, relays will be
opened to immediately isolate the ESS. If error F0044 has not been raised, it may be
possible to resolve the error by restarting the charge
The vehicle will not be able to start again after using a compatible EVSE.
shutdown.
Note: When requested to connect the
vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

217
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 25
Fault code F0006 and Charge end reason 25
Fault code F0007 and Charge end reason 25

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0044 been raised Yes

Refer to the F0044
previously during or before
troubleshooting tree.
this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
218
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. EVSE.

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, F0041, or F0042. If this is the possible to resolve the error by restarting the charge
case, the technician should troubleshoot the specific using a compatible EVSE.
error. Note: When requested to connect the
vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

219
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 26
Fault code F0006 and Charge end reason 26
Fault code F0007 and Charge end reason 26

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0041, F0042 or Yes

Refer to the corresponding error
F0026 been raised previously
troubleshooting tree.
during or before this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation. 220
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. If possible to resolve the error by restarting the charge
this is the case, the technician should troubleshoot using a compatible EVSE.
the specific error.
Note: When requested to connect the
vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

221
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 27
Fault code F0006 and Charge end reason 27
Fault code F0007 and Charge end reason 27

Unplug charger and put the

vehicle in accessory mode.

Access the fault log on the HMI.

Has error F0047, F0026, Yes

F0153, F0154 been raised Refer to the corresponding error
previously during or before troubleshooting tree.
this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation. 222
Troubleshooting

F0005, F0006, F0007 (Charge end reason 28)

Error Description Possible Causes Possible Solutions

VCU has reported that charging 1) Calibration error. 1) Contact Dana.

was ended due to a calibration
error.

It may be possible to resolve the error by restarting Note: When requested to connect the
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

Fault code F0005 and Charge end reason 28
Fault code F0006 and Charge end reason 28
Fault code F0007 and Charge end reason 28

Contact Dana for further

investigation.

223
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.
2) EVSE error. 2) Restart charge session.

This message is not displayed to the driver but may Note: When requested to connect the
still appear in the HMI fault log. If charge controller vehicle to an EVSE, either a level 2 or level
fault reason 29 appears without any other errors and 3 EVSE can be used.
the SOC is at 100% or other operator-defined
maximum, then the charging system is operating
correctly, and no troubleshooting is needed.
Otherwise, it may be possible to resolve the error by
restarting the charge with a compatible EVSE.

224
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 29
Fault code F0006 and Charge end reason 29
Fault code F0007 and Charge end reason 29

100% What is the level of Other

charge desired set in the
parameters of the EVSE?

Has the message been Has the message been

raised after the vehicle has Yes Yes raised after the vehicle has been
been charged and the SOC has Complete charged and the SOC has
reached 100% on both reached the desired level on both
High Voltage batteries? High Voltage batteries?

No
Turn ignition OFF and unplug the
EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Is the truck able to Yes

Reconnect a compatible EVSE to charge completely to
Complete
start charge. 100% without raising the
same fault?

Contact Dana for further

investigation.
225
Troubleshooting

F0005, F0006, F0007 (Charge end reason 30)

Error Description Possible Causes Possible Solutions

This message is not displayed to the driver but may Note: When requested to connect the
still appear in the HMI fault log. If charge controller vehicle to an EVSE, either a level 2 or level
fault reason 30 appears without any other errors and 3 EVSE can be used.
the SOC is at 100% or other operator-defined
maximum, then the charging system is operating
correctly, and no troubleshooting is needed.
Otherwise, it may be possible to resolve the error by
restarting the charge with a compatible EVSE.

226
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 30
Fault code F0006 and Charge end reason 30
Fault code F0007 and Charge end reason 30

100% What is the level of Other

charge desired set in the
parameters of the EVSE?

Has the message been Has the message been

No
Turn ignition OFF and unplug the
EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Is the truck able to Yes

Reconnect a compatible EVSE to charge completely to
Complete
start charge. 100% without raising the
same fault?

Contact Dana for further

investigation.
227
Troubleshooting

F0005, F0006, F0007 (Charge end reason 31)

Error Description Possible Causes Possible Solutions

This message is not displayed to the driver but may Note: When requested to connect the
still appear in the HMI fault log. If charge controller vehicle to an EVSE, either a level 2 or level
fault reason 31 appears without any other errors and 3 EVSE can be used.
the SOC is at 100% or other operator-defined
maximum, then the charging system is operating
correctly, and no troubleshooting is needed.
Otherwise, it may be possible to resolve the error by
restarting the charge with a compatible EVSE.

228
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 31
Fault code F0006 and Charge end reason 31
Fault code F0007 and Charge end reason 31

100% What is the level of Other

charge desired set in the
parameters of the EVSE?

Has the message been Has the message been

No
Turn ignition OFF and unplug the
EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Is the vehicle able to Yes

Reconnect a compatible EVSE to charge completely to
Complete
start charge. 100% without raising the
same fault?

Contact Dana for further

investigation.
229
Troubleshooting

F0005, F0006, F0007 (Charge end reason 32)

Error Description Possible Causes Possible Solutions

This message is not displayed to the driver but may

still appear in the HMI fault log. If charge controller Note: For best ESS performance and
fault reason 32 appears without any other errors and vehicle range HV batteries must regularly be
the SOC is at 100% or other operator-defined changed to 100% SOC. Vehicle SOC is a
maximum, then the charging system is operating calculated valued that drifts over time. It is
correctly, and no troubleshooting is needed. recalibrated only at the end of the charge
Otherwise, it may be possible to resolve the error by cycle when HV batteries are charged to
restarting the charge with a compatible EVSE. 100%. Always fully change the vehicle until
the charge cycle automatically ends. Only
Note: When requested to connect the charge vehicle using a level 2 or level 3
vehicle to an EVSE, either a level 2 or level EVSE.
3 EVSE can be used.

230
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 32
Fault code F0006 and Charge end reason 32
Fault code F0007 and Charge end reason 32

100% What is the level of Other

charge desired set in the
parameters of the EVSE?

Has the message been Has the message been

No
Turn ignition OFF and unplug the
EVSE if applicable.

Wait for vehicle shutdown and

wait 2 minutes after shutdown.

Is the vehicle able to Yes

Reconnect a compatible EVSE to charge completely to
Complete
start charge. 100% without raising the
same fault?

Contact Dana for further

investigation.
231
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.

232
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 33
Fault code F0006 and Charge end reason 33
Fault code F0007 and Charge end reason 33

Has error “Charge

Controller No contact” Yes
Refer to the “Charge Controller
been raised previously
No contact” troubleshooting tree.
during or before this
charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

233
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.

234
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 34
Fault code F0006 and Charge end reason 34
Fault code F0007 and Charge end reason 34

Has error “OBC No Yes

contact” or F0088 been Refer to the corresponding
raised previously during or troubleshooting tree.
before this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

235
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.
seconds if charge is not aborted by 2) Restart charge session.
the charge controller the VCU
aborts itself.)

This fault code is a status message indicating that If charge controller fault reason 35 appears without
the VCU has determined that charging is completed. any other errors and the SOC is at 100% then the
If the charge controller does not terminate the charging system is operating correctly, and no
charge within 5 seconds, the VCU will terminate the troubleshooting is needed. Otherwise, it may be
charge. possible to resolve the error by restarting the charge
with a compatible EVSE.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

236
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 35
Fault code F0006 and Charge end reason 35
Fault code F0007 and Charge end reason 35

Has the message been

raised after the vehicle has Yes
been charged and the SOC has Complete
reached 100% on both
High Voltage batteries ?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.

237
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. If neither of these errors vehicle to an EVSE, either a level 2 or level
is raised, it may be possible to resolve the error by 3 EVSE can be used.
restarting the charge with a compatible EVSE.

238
Troubleshooting

HMI displays or logs

Fault code F0005 and Charge end reason 36
Fault code F0006 and Charge end reason 36
Fault code F0007 and Charge end reason 36

Has error F0027 or Yes

F0026 been raised Refer to the corresponding
previously during or before troubleshooting tree.
this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact DANA for further

investigation.

239
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.
code in the table below. The table gives the specific
troubleshooting tree (numbered TT1 through TT6) Detailed explanations of each fault code are
corresponding to each error code. These trees are provided in the TM4 OBC troubleshooting guide.
presented in the following pages.

OBC Fault Reason Codes

OBC OBC OBC OBC OBC

Fault Tree Fault Tree Fault Tree Fault Tree Fault Tree
Code Ref. Code Ref. Code Ref. Code Ref. Code Ref.
0x0000 TT6 0x1675 TT1 0x3413 TT1 0x4009 TT6 0x4602 TT1
0x0001 TT1 0x1676 TT1 0x3450 TT1 0x400A TT5 0x4603 TT1
0x0002 TT1 0x1677 TT1 0x3451 TT1 0x400B TT5 0x4604 TT1
0x0003 TT1 0x1678 TT1 0x3452 TT1 0x400C TT5 0x4605 TT6
0x0004 TT6 0x1679 TT1 0x3453 TT1 0x400D TT1 0x4606 TT6
0x0005 TT1 0x1800 TT1 0x3454 TT1 0x400E TT1 0x4607 TT1
0x0006 TT1 0x1801 TT1 0x3455 TT1 0x400F TT1 0x4608 TT1
0x0007 TT1 0x1802 TT1 0x3456 TT1 0x4010 TT1 0x4609 TT1
0x0008 TT1 0x1803 TT1 0x3457 TT1 0x4011 TT1 0x460A TT1
0x0009 TT1 0x1850 TT1 0x3458 TT1 0x4012 TT1 0x460B TT1
0x000A TT1 0x1851 TT1 0x3459 TT1 0x4013 TT1 0x460C TT1
0x000B TT1 0x1852 TT1 0x345A TT1 0x4014 TT1 0x5300 TT6
0x000C TT6 0x1853 TT1 0x345B TT1 0x4100 TT1 0x5301 TT4
0x1300 TT6 0x2000 TT1 0x345C TT1 0x4101 TT1 0x5302 TT1
0x1301 TT1 0x2001 TT1 0x345D TT1 0x4102 TT1 0x5303 TT1
0x1400 TT6 0x2200 TT1 0x345E TT1 0x4103 TT1 0x5304 TT6
0x1401 TT1 0x2201 TT1 0x345F TT1 0x4104 TT1 0x5305 TT1
0x1500 TT1 0x2500 TT1 0x3460 TT1 0x4105 TT1 0x5306 TT1
0x1501 TT1 0x2501 TT1 0x3500 TT1 0x4106 TT1 0x5307 TT1
0x1502 TT1 0x2550 TT1 0x3501 TT1 0x4107 TT1 0x5400 TT1
0x1503 TT1 0x2551 TT1 0x3502 TT1 0x4108 TT1 0x5401 TT3
0x1504 TT1 0x3300 TT6 0x3503 TT1 0x4109 TT6 0x5402 TT3
0x1525 TT1 0x3301 TT1 0x3504 TT1 0x410A TT5 0x5403 TT1
0x1526 TT1 0x3302 TT1 0x3505 TT3 0x410B TT5 0x5404 TT1
0x1527 TT1 0x3303 TT1 0x3506 TT3 0x410C TT5 0x5405 TT1
0x1528 TT1 0x3304 TT6 0x3507 TT1 0x410D TT1 0x5406 TT3
0x1529 TT1 0x3305 TT1 0x3508 TT1 0x410E TT1 0x5407 TT3
0x1550 TT1 0x3306 TT1 0x3509 TT1 0x410F TT1 0x5408 TT1
0x1551 TT1 0x3307 TT1 0x350A TT1 0x4110 TT1 0x5409 TT1
0x1552 TT1 0x3308 TT1 0x350B TT1 0x4111 TT1 0x540A TT1
0x1553 TT1 0x3309 TT1 0x350C TT1 0x4112 TT1 0x540B TT1
240
Troubleshooting

OBC OBC OBC OBC OBC

Fault Tree Fault Tree Fault Tree Fault Tree Fault Tree
Code Ref. Code Ref. Code Ref. Code Ref. Code Ref.
0x1554 TT1 0x330A TT1 0x350E TT1 0x4113 TT1 0x5500 TT1
0x1575 TT1 0x330B TT1 0x350F TT1 0x4114 TT1 0x5501 TT1
0x1576 TT1 0x3400 TT1 0x3510 TT1 0x4115 TT1 0x5502 TT1
0x1577 TT1 0x3401 TT1 0x3600 TT1 0x4116 TT1 0x5503 TT1
0x1578 TT1 0x3402 TT1 0x3601 TT1 0x4117 TT1 0x5504 TT1
0x1579 TT1 0x3403 TT1 0x3602 TT1 0x4118 TT1 0x5505 TT1
0x1600 TT1 0x3404 TT1 0x3700 TT1 0x4200 TT1 0x5506 TT3
0x1601 TT1 0x3405 TT1 0x3725 TT2 0x4201 TT1 0x5507 TT3
0x1602 TT1 0x3406 TT1 0x3726 TT1 0x4202 TT1 0x5508 TT1
0x1603 TT1 0x3407 TT1 0x3727 TT2 0x4203 TT1 0x5509 TT1
0x1604 TT1 0x3408 TT2 0x3728 TT2 0x4204 TT1 0x5600 TT3
0x1625 TT1 0x3409 TT2 0x3729 TT2 0x4205 TT6 0x5601 TT1
0x1626 TT1 0x340A TT2 0x3750 TT4 0x4206 TT6 0x5602 TT1
0x1627 TT1 0x340B TT1 0x3751 TT6 0x4207 TT1 0x5650 TT1
0x1628 TT1 0x340C TT1 0x4002 TT1 0x4208 TT1 0x5651 TT1
0x1629 TT1 0x340D TT1 0x4003 TT1 0x4209 TT1 0x5652 TT6
0x1650 TT1 0x340E TT2 0x4004 TT1 0x420A TT1 0x5653 TT6
0x1651 TT1 0x340F TT2 0x4005 TT1 0x420B TT1 0x5654 TT1
0x1652 TT1 0x3410 TT1 0x4006 TT1 0x420C TT1
0x1653 TT1 0x3411 TT1 0x4007 TT1 0x4600 TT1
0x1654 TT1 0x3412 TT1 0x4008 TT1 0x4601 TT1

241
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,
0x0009, 0x000A, 0x000B, 0x1301, 0x1401, 0x4005, 0x4006, 0x4007, 0x4008, 0x400D,
0x1500, 0x1501, 0x1502, 0x1503, 0x1504, 0x400E, 0x400F, 0x4010, 0x4011, 0x4012,
0x1525, 0x1526, 0x1527, 0x1528, 0x1529, 0x4013, 0x4014, 0x4100, 0x4101, 0x4102,
0x1550, 0x1551, 0x1552, 0x1553, 0x1554, 0x4103, 0x4104, 0x4105, 0x4106, 0x4107,
0x1575, 0x1576, 0x1577, 0x1578, 0x1579, 0x4108, 0x410D, 0x410E, 0x410F, 0x4110,
0x1600, 0x1601, 0x1602, 0x1603, 0x1604, 0x4111, 0x4112, 0x4113, 0x4114, 0x4115,
0x1625, 0x1626, 0x1627, 0x1628, 0x1629, 0x4116, 0x4117, 0x4118, 0x4200, 0x4201,
0x1650, 0x1651, 0x1652, 0x1653, 0x1654, 0x4202, 0x4203, 0x4204, 0x4207, 0x4208,
0x1675, 0x1676, 0x1677, 0x1678, 0x1679, 0x4209, 0x420A, 0x420B, 0x420C, 0x4600,
0x1800, 0x1801, 0x1802, 0x1803, 0x1850, 0x4601, 0x4602, 0x4603, 0x4604, 0x4607,
0x1851, 0x1852, 0x1853, 0x2000, 0x2001, 0x4608, 0x4609, 0x460A, 0x460B, 0x460C,
0x2200, 0x2201, 0x2500, 0x2501, 0x2550, 0x5302, 0x5303, 0x5305, 0x5306, 0x5307,
0x2551, 0x3301, 0x3302, 0x3303, 0x3305, 0x5400, 0x5403, 0x5404, 0x5405, 0x5408,
0x3306, 0x3307, 0x3308, 0x3309, 0x330A, 0x5409, 0x540A, 0x540B, 0x5500, 0x5501,
0x330B, 0x3400, 0x3401, 0x3402, 0x3403, 0x5502, 0x5503, 0x5504, 0x5505, 0x5508,
0x3404, 0x3405, 0x3406, 0x3407, 0x340B, 0x5509, 0x5601, 0x5602, 0x5650, 0x5651,
0x340C, 0x340D, 0x3410, 0x3411, 0x3412, and 0x5654.
0x3413, 0x3450, 0x3451, 0x3452, 0x3453,
0x3454, 0x3455, 0x3456, 0x3457, 0x3458, Caution: Make sure the vehicle is in driving
0x3459, 0x345A, 0x345B, 0x345C, 0x345D, mode when performing any update to the
0x345E, 0x345F, 0x3460, 0x3500, 0x3501, OBC software.
0x3502, 0x3503, 0x3504, 0x3507, 0x3508,

HMI displays or logs

Fault code F0088

Refer to the tabulated section in the

TM4 troubleshooting guide to find
the proper troubleshooting tree in
the TM4 troubleshooting guide.

242
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.

3) Incompatible or defective 3) Restart charge with compatible

EVSE. EVSE.

4) Loss of continuity due to 4) Replace LV connector or

defective LV connector or harness per Service Manual.
harness.
5) Resolve CAN communication
5) CAN communication problem. problem.

6) OBC internal error. 6) Replace OBC.

Note: This troubleshooting tree covers the

following OBC fault codes: 0x3408, 0x3409,
0x340A, 0x340E, 0x340F, 0x3725, 0x3727,
0x3728, and 0x3729.

Caution: Make sure the vehicle is in driving

mode when performing any update to the
OBC software.

Connector C22

Connector C11 (black)

Connector C12 (gray) Connector C100

243
Troubleshooting

HVIL 1

HVIL 2
Connector C727
3

Connector C706

Connector C731

Connector C726

244
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

No
occurring on further
Complete
key ON or charge
cycles?

Yes

Disconnect EVSE and restart charge

with a different level 2 EVSE.

No
Is the error still being
Complete
raised on the HMI?

Yes

Does the HMI also Yes

Refer to the corresponding error
display F0006 or
troubleshooting tree.
F0007?

No
Continued on next page

245
Troubleshooting

No 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. charge inlet.

With a multimeter, check for continuity between the

following points: Refer to connector investigation
OBC C22 MPDM C11 subtree.
Connector Connector
Pin 21 Pin E
OBC C22 MPDM C12
Connector Connector
Pin 23 Pin H Yes
Is there any problem with Defective connector.
OBC C22 Ground C100 the connector integrity? Replace harness.
Connector Connector
Pin 22 Pin 1

OBC C731P HV JB C706P

No
Connector Connector
Pin 1 Pin 1
OBC C731P HV JB C706P
Connector Connector
Pin 2 Pin 2

RT053 RT052
Connector Connector
Pin 2 Pin 2
OBC C727P Charge inlet C726P
Connector Connector
Pin 2 Pin N

Pin 3 Pin L1

Pin 1 Pin PE

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

246
Troubleshooting

Continued from previous page

Is there any evidence of Yes Defective harness.

a continuity loss? Replace harness.

Do any of the bolted

connections appear Yes Defective connection point.
scorched, corroded, or Repair or replace appropriately.
dirty?

Refer to CAN investigation subtree.

Investigate CAN B network.
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed ?
network? subtree.

No Yes

Defective OBC.
Replace OBC.

247
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.

4) Loss of continuity due to 4) Replace HV harness.

defective HV connector or
harness. 5) Resolve CAN communication
problem.
5) CAN communication problem.
6) Replace OBC.
6) OBC internal error.

Note: This troubleshooting tree covers the

following OBC fault codes: 0x3505, 0x3506, 3
0x5401, 0x5402, 0x5406, 0x5407, 0x5506, 4
0x5507, and 0x560.

Caution: Make sure the vehicle is in driving

mode when performing any update to the
OBC software.
3

Connector C702

Connector C701

Connector C706

248
Troubleshooting

Connector C716 (black) Connector C719 (orange)

Connector C717 (green)

Connector C731

Connector C718 (yellow)

249
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 Yes

Yes
occurring on further Does the HMI also Refer to Error F0026
key ON or charge display F0026? troubleshooting tree.
cycles?

No
No

Complete

Disconnect connector C706, C702 and WARNING: Electrical hazard.

C701 from HV Junction box.
Disconnect connector C731 from OBC. Follow Safety Warnings and High
Disconnect connector C718, C719, C716 Voltage Shutdown Procedures
and C717 from S-box. defined in the Service Manual
and Diagnostic Guide.

Refer to connector investigation

subtree.

Continued on next page

250
Troubleshooting

Continued from previous page

Is there any problem with Yes 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

Connector Connector
Pin 1 Pin 1
S-Box C719P HV JB C702P
Connector Connector

Pin 1 Pin 2

S-Box C716P HV JB C701P

Connector Connector
Pin 1 Pin 1
S-Box C717P HV JB C701P
Connector Connector

Pin 1 Pin 2
RT056 RT057
Connector Connector

RT056 RT057

RT052 RT053
Connector Connector

RT056 RT057

- Continuity : Resistance is less than or equal to 2ohms.

Refer to CAN investigation subtree. No Is there any evidence of Yes Defective harness.
Investigate CAN B network. continuity loss? Replace harness.

Continued on next page

251
Troubleshooting

Continued from previous page

Were you able to find a Yes Repair according to the No

Is the error code still
problem in the CAN B actions prescribed in the
displayed?
network? subtree.

No Yes

Observing proper safety

precautions, open the HV Complete
junction box.
WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Yes Replace fuse and inform

Is High Voltage fuse F2
DANA before taking further
blown or intermittent?
actions.

Defective OBC.
Replace OBC.

Yes Is the error still occurring on No

Contact Dana for further
investigation. further key ON or charge Complete
cycles?

252
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.

4) OBC internal error. 4) Replace OBC.

Note: This troubleshooting tree covers the Caution: Make sure the vehicle is in driving
following OBC fault codes: 0x3750 and mode when performing any update to the
0x5301. OBC software.

253
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 No

on further key ON or Complete
charge cycles?

Yes

Does the HMI also Yes

Refer to the corresponding error
display F0059 or
troubleshooting tree.
F0060?

Refer to cooling system

investigation subtree.

Could you find any Yes Repair or replace any piece as per
defect that would cause the cooling circuit investigation
the OBC to overheat? subtree instructions.

Defective OBC.
Replace OBC.

254
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.

Note: This troubleshooting tree covers the Caution: Make sure the vehicle is in driving
following OBC fault codes: 0x400A, 0x400B, mode when performing any update to the
0x400C, 0x410A, 0x410B, and 0x410C. OBC software.

255
Troubleshooting

HMI displays or logs

Fault code F0088 and
OBC fault reason 0x400C/ 0x400B,
0x410A/0x410C/0x400A/0x410B

Update the OBC software version

following the STT01 tree provided in
the TM4 troubleshooting guide.

Is the error still occurring No

on further key ON or Complete
charge cycles?

Yes

Refer to CAN investigation subtree

Investigate CAN B network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

256
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.
0x3751, 0x4009, 0x4109, 0x4205, 0x4206,
0x4605, 0x4606, 0x5300, 0x5304, 0x5652, If a problem is present, one or more additional OBC
and 0x5653. fault reason codes will also appear. The technician
should troubleshoot the other fault code(s).

HMI displays or logs

Fault code F0088 and
OBC fault reason...

No actions required

257
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. 3) Replace OBC.

3) OBC internal failure.

HVIL pin 1
The purpose of the HVIL is to provide a warning if
any HV connector is unplugged without the HV
distribution being safely ended. The OBC monitors
continuity between the HVIL pins on its HV
connectors (C727 and C731). If this connector is
unplugged unsafely, the HVIL will be broken and the
OBC will send an error message via CAN.

If one of the analog HVIL errors (F0061, F0062, or Connector C727

F0063) is raised, the problem may be an unplugged HVIL pin 2
connector or other discontinuity elsewhere on the
analog HVIL. The technician should refer to the
analog HVIL troubleshooting subtree to locate the
problem.

If none of F0061, F0062, or F0063 are raised, the

problem is may be local to connector C727 or C731.
The connector may be unplugged or there may be a
loss of continuity between its HVIL pins.

Connector C731

258
Troubleshooting

HMI displays or logs

Fault code F0088 and
OBC HVIL error

Yes
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.
defined in the Service Manual
and Diagnostic Guide.

Is there any
With a multimeter, check for continuity between the Yes
problem with the Defective connector.
following points:
connector Replace harness.
OBC C731P OBC C731P integrity?
Connector Connector
Pin HVIL_A Pin HVIL_B
No
OBC C727S OBC C727S
Connector Connector
Pin HVIL1 Pin HVIL2

- Continuity : Resistance is less than or equal to 2ohms.

Defective OBC. No Is there any evidence of Yes Defective harness.

Replace OBC. a continuity loss? Replace harness.

259
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. charging.
discharged during charging.
2) Incompatible or defective 2) Restart charge with compatible
EVSE. EVSE.

3) ESS fault. 3) Troubleshoot specific error.

Note: When requested to connect the

vehicle to an EVSE, either a level 2 or level
3 EVSE can be used.

260
Troubleshooting

HMI displays or logs

Fault code F0131

Turn OFF cabin heater and air

conditioning if applicable.

Has error F0026 been Yes

Refer to the F0026
raised previously during
troubleshooting tree.
or before this charge?

Turn ignition OFF and unplug the

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 Yes

charge completely to
Complete
100% without raising the
same fault?

Contact Dana for further

investigation.
261
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. defective LV connector or harness per Service Manual.
harness.
3) Resolve CAN communication
3) CAN communication problem. problem.

4) Charge controller internal 4) Replace charge controller.

failure.

No Contact fault messages appear on the HMI Note: The charge controller is connected to
display and remain while the fault is active. all five CAN networks, but communication
Historical No Contact fault messages can be found between the charge controller and VCU
in the HMI logs by selecting the MC43[2]log. occurs on CAN A.

Connector C50
Connector C12 (gray)

Connector C40

Connector C52

262
Troubleshooting

Connector C53

Connector C100

263
Troubleshooting

HMI displays “Charge Controller

No Contact.”

Does the HMI also

display “F0072 - Yes 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.
Disconnect connector C100 from ground.

With a multimeter, check for continuity between the

Defective connector.
following points:
Replace the connector as
CCU C52 C50P Is there any problem with Yes described in the “Wire Harness
Connector Connector the connector integrity? Connector Identification,
Location, and Service Chart” in
Pin H4 Pin C
the Service Manual
CCU C53 C50P
Connector Connector

Pin M1 Pin C

C40P C50S
Connector Connector No
Pin 26 Pin C

Pin 26 Pin B
MPDM C12 C40S
Connector Connector

Pin D Pin 26
CCU C52 C50P
Connector Connector
Pin G4 Pin B

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

264
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.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to CAN investigation subtree

Investigate CAN B network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed ?
network ? subtree.

No Yes

Defective charge controller.

Replace charge controller.

265
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.
defective LV connector or
harness. 3) Resolve CAN communication
problem.
3) CAN communication problem.
4) Replace OBC.
4) OBC internal 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.

Connector C11 (black)

Connector C22

Connector C12 (gray)

Connector C100

266
Troubleshooting

HMI displays “OBC No contact.”

Refer to CAN investigation subtree.

Investigate CAN B network. Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed?
network? subtree.

No Yes

Yes
Does the HMI also display Refer to the MPDM No contact
“MPDM No contact”? troubleshooting tree.

Yes
Does the HMI also display Refer to the corresponding error
F0070, F0075 or F0082? troubleshooting tree.

Disconnect connector C22 from OBC.

Refer to connector investigation

subtree.

Continued on next page

267
Troubleshooting

Continued from previous page

No
With a multimeter measure the voltage between the
following points:
OBC C22 OBC C22
Connector Connector
Pin 23 Pin 22
OBC C22 OBC C22
Connector Connector
Pin 21 Pin 22 Refer to the specific
troubleshooting tree.

Yes

No Does the HMI also

Defective OBC. Is the voltage 11V
display F0095 or
Replace OBC. or higher?
Yes F0008?

Disconnect connector C11 and C12

from MPDM.
Turn ignition OFF.
Disconnect connector C100 from
ground.

Refer to connector investigation

subtree.

Continued on next page

268
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
OBC 22 MPDM C11
Connector Connector
Pin 21 Pin E
OBC 22 MPDM C12
Connector Connector
Pin 23 Pin H

OBC 22 Ground C100

Connector Connector
Pin 22 Pin 1

- Continuity : Resistance is less than or equal to 2ohms.

Is there any evidence of Yes Defective harness.

a continuity loss or a
Replace harness.
degraded connection?

Contact Dana for further

investigation.

269
Troubleshooting

Propulsion System
The propulsion system converts electrical energy Traction Inverter
from the ESS into mechanical energy to propel the
truck. It consists of an electric motor and a Traction The traction inverter is the inverter and control unit
inverter. The propulsion system is available in two which supplies and controls the motor. The control
configurations medium duty and heavy duty. stage is powered by 12V low voltage from the
MPDM and communicates via the CAN B network.
Component descriptions The power stage (inverter) is powered by high
voltage.
Motor
Accelerator Pedal
The motor provides the power to propel the vehicle.
It is powered by AC high voltage supplied by the The accelerator pedal transmits requests for traction
traction inverter. from the driver to the propulsion system. The pedal
position is detected by two redundant sensors and is
communicated via the CAN C network and dedicated
LV signals.

270
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. 2) ESS or HV distribution fault.
3) Resolve CAN communication
3) CAN communication problem. problem.

This error can occur if the vehicle is traveling at appear. The technician should troubleshoot the
maximum speed or on a steep slope, or if specific error.
regenerative braking is not possible because the
high voltage batteries are near 100% state of charge The error may also be raised if the traction inverter is
(SOC). In these cases, the vehicle is functioning not able to receive the current measurement via
normally and no troubleshooting is needed. CAN.

This error can also appear if there is a problem with Propulsion System faults may also be
the HV network. In this case, error F0026 and/or investigated and resolved using the ODIN
other errors raised by devices on the network should tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

271
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 1
Fault code F0098 and Fault reason 1

Was this error raised in a No Yes

Is the SOC approaching
steep slope or at maximum Complete
high limit?
speed?

Yes
No

Complete
Yes
Does the HMI also Refer to the F0026
display F0026? troubleshooting tree.

No
Refer to the CAN investigation
subtree.
Investigate CAN B and A network.

Were you able to find a Yes

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.

272
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. calibration error. software and calibration.

3) Traction inverter internal 3) Replace traction inverter.

failure.

This error could also be raised if there is a

problem with the high voltage batteries. In this
case error F0026 should appear and the
technician should troubleshoot error F0026.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

4 3

4 3
Connector C702

Connector C701

Connector C716 (black)

273
Troubleshooting

Connector C717 (green) Connector C719 (orange)

Connector C718 (yellow)

274
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 2
Fault code F0098 and Fault reason 2

Yes
Does the HMI also Refer to the F0026
display F0026? troubleshooting tree.

Yes Is any other system on

the high voltage bus
raising an error?

Flash the traction inverter to the latest

software and calibration following the
instructions in the TM4 installation
manual.

Is the problem Yes

Defective traction inverter.
persisting on further
Replace traction inverter.
drive cycles?
WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual No
and Diagnostic Guide.
Complete

Continued on next page

275
Troubleshooting

Continued from previous page

Disconnect connector C701 and

C702 from HV junction box.
Disconnect connector C718, C719,
C716 and C717 from S-Box.

Refer to the connector investigation

subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

With a multimeter, check for continuity between the

following points:
HV JB C702P S-Box C718P
Connector pin Connector pin
Pin 1 Pin 1

HV JB C702P S-Box C719P

Connector pin Connector pin
Pin 1 Pin 1
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.

Yes
Is there any evidence of Defective harness.
a continuity loss? Replace harness.

Contact Dana for further

investigation. 276
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. software and calibration.

3) Loss of continuity between 3) Replace LV connector or

traction inverter and speed harness per Service Manual.
sensor due to defective LV
connector or harness. 4) Replace traction inverter.

4) Traction inverter internal 5) Replace motor.

failure.

5) Motor internal failure.

This error can occur if the vehicle is traveling over 70 Propulsion System faults may also be
mph or on a steep slope. In these cases, the vehicle investigated and resolved using the ODIN
is behaving normally and no troubleshooting is tool and the TM4 SUMO Powertrain
needed. Troubleshooting Guide.

277
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 Yes

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.

Is the problem No
persisting on further
Complete
drive cycles in similar
conditions?

Yes

With a multimeter check for wiring

continuity and short circuits on the
harness connecting the motor speed
sensor to the motor inverter.

Continued on next page

278
Troubleshooting

Continued from previous page

Is there any evidence of a Yes

short or a conductivity Defective harness.
problem on the speed sensor Replace harness.
cables?

Refer to connector investigation

subtree.
Inspect the traction inverter
connectors.

Yes
Were there any defects on the Defective traction inverter.
traction inverter? Replace traction inverter.

Defective motor.
Replace motor.

279
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 2) Cooling fault. down for 2 hours.
overheating in the motor or traction
inverter. 3) Cooling system problem. 2) Troubleshoot specific error.

4) Traction inverter internal 3) Resolve cooling system

failure. problem.

4) Replace traction inverter.

This error can occur if the ambient temperature is Propulsion System faults may also be
very high or if driving conditions are very taxing investigated and resolved using the ODIN
(maximum speed, maximum torque, steep uphill or tool and the TM4 SUMO Powertrain
downhill). In these cases, the problem can be Troubleshooting Guide.
resolved by allowing the vehicle to cool down.

280
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 4
Fault code F0098 and Fault reason 4

Did the fault clear Yes

during normal Complete
operation?

Did the error occur under

extreme conditions: Max speed, Yes Let the truck cool down for 2 hours
Max torque, steep uphill/ parked outside not under the sun
downhill, extremely hot with the ignition switched OFF.
temperature?

Is error F0059 or F0060, Yes

Refer to the specific error
F0109 or F0110 displayed
troubleshooting tree.
on the HMI?

No
Continued on next page

281
Troubleshooting

No Continued from previous page

Is the VCU displaying Yes

Refer to the specific error
‘’Powertrain Coolant
troubleshooting tree.
Pump No Contact’’?

Is the VCU displaying Yes

‘’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.

Were you able to find a Yes

defect in the cooling system Repair as per the subtree
causing this error to be instructions.
raised?

Defective traction inverter.

Replace traction inverter.

282
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. 2) Traction inverter internal 2) Replace traction inverter.
failure.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

HMI displays or logs

Fault code F0097 and Fault reason 5
Fault code F0098 and Fault reason 5

Flash the traction inverter to the latest

software and calibration following the
instructions in the TM4 installation
manual.

Is the problem No
persisting on further
Complete
drive cycles in similar
conditions?

Yes

Defective traction inverter.

Replace traction inverter.

283
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. software and calibration.
maximum power rating.
3) Traction inverter internal 3) Replace traction inverter.
failure.

This error can occur if the vehicle is traveling at Propulsion System faults may also be
maximum speed or on a steep slope. In this case, investigated and resolved using the ODIN
the vehicle is functioning normally and no tool and the TM4 SUMO Powertrain
troubleshooting is needed. Troubleshooting Guide.

284
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 6
Fault code F0098 and Fault reason 6

Was this error raised on a Yes

steep slope or at maximum Complete
speed?

Flash the traction inverter to the latest

software and calibration following the
instructions in the TM4 installation
manual.

Is the problem No
persisting on further
Complete
drive cycles in similar
conditions?

Yes

Contact Dana for further

investigation.

285
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. harness. 3) Refer to traction inverter
troubleshooting guide.
3) Causes covered in traction
inverter troubleshooting guide. 4) Update traction inverter
software and calibration.
4) Traction inverter software or
calibration error.

In the event of an actual problem with the HV

network, error F0026 and/or other errors raised by
devices on the network should appear. The cause
may be a loss of continuity on the HV network.

If this is not the case, the technician should refer

to the traction inverter troubleshooting guide. It is
also possible that the problem could be resolved
by updating the traction inverter software and
calibration.

Propulsion System faults may also be

investigated and resolved using the ODIN
4 3
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

Connector C702

4 3

Connector C701

286
Troubleshooting

Connector C716 (black) Connector C718 (yellow)

Connector C717 (green) Connector C719 (orange)

287
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 7
Fault code F0098 and Fault reason 7

No Is any other system on Yes

Does the HMI also
display F0026?
the high voltage bus
raising an error?
A
A

No
Yes

Refer to the TM4 troubleshooting

Refer to the F0026 guide for further investigation.
troubleshooting tree. Refer to TT18 and TT19 in the TM4
guide.

Yes Could you solve the error

following the instructions
provided in the TM4 guide?

Flash the traction inverter to the latest

No Is the problem
software and calibration following the
Complete persisting on further
instructions in the TM4 installation
drive cycles?
manual.

Yes

Contact Dana for further

investigation.

288
Troubleshooting

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Disconnect connector C701 and

C702 from HV junction box.
Disconnect connector C718,
C719, C716 and C717 from S-
Box.

Refer to the connector investigation

subtree.

Is there any
problem with the Yes Defective connector.
connector Replace harness.
integrity?

With a multimeter, check for continuity between the

Defective harness.
following points:
Replace harness.
HV JB C702P S-Box C718P
Connector pin Connector pin
Yes
Pin 1 Pin 1

HV JB C702P S-Box C719P

Connector pin Connector pin
Pin 1 Pin 1 Is there any evidence of
a continuity loss?
HV JB C701P S-Box C717P
Connector pin Connector pin
Pin 1 Pin 1
HV JB C701P S-Box C716P
Connector pin Connector pin
No
Pin 1 Pin 1

- Continuity : Resistance is less than or equal to 2ohms. Contact Dana for further
investigation.

289
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 2) Cooling fault. down for 2 hours.
overheating in the traction inverter.
3) Cooling system problem. 2) Troubleshoot specific error.

4) Traction inverter internal 3) Resolve cooling system

failure. problem.

4) Replace traction inverter.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

290
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 8
Fault code F0098 and Fault reason 8

Did the fault clear Yes

during normal Complete
operation?

Did the error occur under

extreme conditions: Max speed, Yes Let the truck cool down for 2 hours
Max torque, steep uphill/ parked outside not under the sun
downhill, extremely hot with the ignition switched OFF.
temperature?

Is error F0059 or F0060, Yes

Refer to the specific error
F0109 or F0110 displayed on
troubleshooting tree.
the HMI?

No
Continued on next page

291
Troubleshooting

No Continued from previous page

Is the VCU displaying Yes

Refer to the specific error
‘’Powertrain Coolant
troubleshooting tree.
Pump No Contact’’?

Is the VCU displaying Yes

‘’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.

Were you able to find a Yes

defect in the cooling system Repair as per the subtree
causing this error to be instructions.
raised?

Defective traction inverter.

Replace traction inverter.

292
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 2) Cooling fault. down for 2 hours.
overheating in the motor.
3) Cooling system problem. 2) Troubleshoot specific error.

3) Resolve cooling system

problem.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

293
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 9
Fault code F0098 and Fault reason 9

Did the fault clear Yes

during normal Complete
operation?

Did the error occur under

extreme conditions: Max speed, Yes Let the truck cool down for 2 hours
Max torque, steep uphill/ parked outside not under the sun
downhill, extremely hot with the ignition switched OFF.
temperature?

Is error F0059 or F0060, Yes

Refer to the specific error
F0109 or F0110 displayed on
troubleshooting tree.
the HMI?

No
Continued on next page

294
Troubleshooting

No Continued from previous page

Is the VCU displaying Yes

Refer to the specific error
‘’Powertrain Coolant
troubleshooting tree.
Pump No Contact’’?

Is the VCU displaying Yes

‘’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.

Were you able to find a Yes

defect in the cooling system Repair as per the subtree
causing this error to be instructions.
raised?

Contact Dana for further

investigation.

295
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.

HMI displays or logs

Fault code F0097 and Fault reason 10
Fault code F0098 and Fault reason 10

Defective motor.
Replace motor.

296
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 2) Traction inverter software or down for 2 hours.
in the high voltage batteries. calibration error.
2) Update traction inverter
software and calibration.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

297
Troubleshooting

HMI displays or logs

Fault code F0097 and Fault reason 11
Fault code F0098 and Fault reason 11

No Did the fault clear Yes

during normal Complete
operation?

Did the error occur under

extreme conditions: Max speed, Yes Let the truck cool down for 2 hours
Max torque, steep uphill/ parked outside not under the sun
downhill, extremely hot with the ignition switched OFF.
temperature?

No
Does the fault occur again during
Complete
a test drive?

Yes

Flash the traction inverter to the latest Yes

Is the problem
software and calibration following the Contact Dana for further
persisting on further
instructions in the TM4 installation investigation.
drive cycles?
manual.

298
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.

3) Loss of continuity between 3) Replace LV connector or

MPDM and traction inverter harness per Service Manual.
due to defective LV connector
or harness. 4) Replace LV connector or
harness per Service Manual.
4) Loss of continuity between
12V fuse box and Charge 5) Replace relay K004.
Controller due to defective LV
connector or harness.

5) Defective relay K004.

The traction inverter will send an emergency stop

request to open an HV relay to prevent a hazardous
situation. The traction inverter will take this action if
its ignition signal is lost during operation or if it
detects an overcurrent condition on its input.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

Connector C4

Connector C11 (black)

Connector C3

299
Troubleshooting

Connector C676

Connector C40

Connector C93P (pin)

Connector C50

Connector C93S (socket)

Connector C53

Connector C91

300
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 Yes
MPDM blown or
intermittent?
A
No

Is fuse F19 on Yes

12V fuse box C14 blown
or intermittent?
B

Is fuse F4 on Yes
MPDM blown or
intermittent?
C
No
Disconnect connector C3 from traction inverter.
Disconnect connector C11 from MPDM.
Disconnect connector C93.
Disconnect connector C4 from K004.
Remove fuse F19 in order to take continuity
measures from inside the fuse box.

Refer to the connector investigation

subtree.

Continued on next page

301
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
MPDM C11 K004 C4
Connector pin Connector pin
Pin H Pin 1
K004 C4 C93S
Connector pin Connector pin
Pin 4 Pin 2
C93P C3 traction inverter
Connector pin Connector pin

Pin 2 Pin G

- Continuity : Resistance is less than or equal to 2ohms.

Is there any Yes

Defective harness.
evidence of
Replace harness.
continuity loss?

Disconnect connector C91.

Disconnect connector C676.
Disconnect connector C40.
Disconnect connector C50.
Disconnect connector C53 from CCU.

Refer to the connector investigation

subtree.

Is there Defective connector.

any problem with Yes 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:
12V fuse box C14 K004 C4
Terminal Connector pin
C9 Pin 5

C91S K004 C4
Connector pin Connector pin

Pin 30 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page 302

Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
C676P C676P
Connector pin Connector pin Defective harness.
Replace harness.
Pin 30 Pin 31
C91S C40S Yes
Connector pin Connector pin

Pin 31 Pin 28
Is there any evidence
C40P C50S of continuity loss?
Connector pin Connector pin

Pin 28 Pin L No

C50P C53
Connector pin Connector pin Replace relay K004.
Pin L Pin K1

- Continuity : Resistance is less than or equal to 2ohms.

Turn ignition back ON

WARNING: Electrical hazard.

Observer proper safety Is error F0099 eventually
precautions, open the HV Follow Safety Warnings and High reoccurring after previous
junction box Voltage Shutdown Procedures Yes troubleshooting?
defined in the Service Manual
and Diagnostic Guide.

No
Inspect fuse F3 in the HV
junction box.
Complete

Is HV fuse F3 fully Yes

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
before restarting the truck. 303
Troubleshooting

Complete

A No

Disconnect blown fuse F5 from Replace fuse F5 on MPDM. Did fuse F5 blow again
MPDM. Restart the vehicle. during test drive?

Yes

Refer to the connector Disconnect connector C11 from Turn ignition OFF and
investigation subtree. MPDM. disconnect F5 from MPDM.

No
Continued on next page

304
Troubleshooting

No
Continued from previous page

With a multimeter, check for short circuit between the

following points:

C11 MPDM Ground

Connector pin
Pin H GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Yes
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 Yes

Contact Dana for further
again during test
investigation.
drive?

Complete

305
Troubleshooting

Complete

B No

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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect C53 and C54 from
disconnect F19 from 12V fuse
investigation subtree. supervisory controller.
box C14.

Continued on next page

306
Troubleshooting

No
Continued from previous page

With a multimeter, check for short circuit between the

following points:

12V fuse box C14 Ground

Terminal
C9 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Yes
Is there any evidence Defective harness.
of a short circuit? Replace harness.

Replace fuse F19 on 12V fuse

box C14.
Replace relay K004 and K005.

Reconnect all previously

disconnected connectors.
Restart the vehicle.

Yes
Did fuse F19 blow again Contact Dana for further
during test drive? investigation.

Complete

307
Troubleshooting

Complete

C No

Disconnect blown fuse F4 from Replace fuse F4 on MPDM. Did fuse F4 blow again
MPDM. Restart the vehicle. during test drive?

Yes

Refer to the connector Disconnect connector C11 Turn ignition OFF and
investigation subtree. from MPDM. disconnect F4 from MPDM.

Continued on next page

308
Troubleshooting

No
Continued from previous page

With a multimeter, check for short circuit between the

following points:

C11 MPDM Ground

Connector pin
Pin B GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Yes
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 No

Complete
during a test drive?

Yes

Contact Dana for further

investigation.

309
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.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

HMI displays or logs

Fault code F0100 and
Traction inverter fault reason 1

Refer to the ‘’Phase Cable(s) Shorted

to Chassis’’ tree in TM4 traction
inverter troubleshooting guide.

310
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.
2) Replace motor.
2) Motor internal failure.
3) Replace traction inverter.
3) Traction inverter internal
failure. 4) Troubleshoot specific error.

4) Analog HVIL fault.

The traction inverter has its own internal interlock Propulsion System faults may also be
system which detects if a connector on the motor or investigated and resolved using the ODIN
traction inverter is unplugged. If a discontinuity is tool and the TM4 SUMO Powertrain
detected between the traction inverter and motor, the Troubleshooting Guide.
traction inverter raises fault reason 2. If a
discontinuity is detected on the traction inverter LV
side, the traction inverter raises fault reason 3.

311
Troubleshooting

HMI displays or logs

Fault code F0100 and
Traction inverter fault reason 2

Does the HMI also No Contact Dana for further

display F0061 or
investigation.
F0062?

Yes

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Disconnect speed sensor

connector from speed sensor.

Refer to the connector

investigation subtree.

Continued on next page

312
Troubleshooting

Continued from previous page

Defective connector.
Replace the connector as
Yes 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.

Is the error
No message still
Complete.
appearing on the
No HMI?

Yes

Using a jumper, connect pin H Disconnect speed sensor

to pin K on the speed sensor connector from speed Turn ignition OFF.
harness connector. sensor.

No
Is the error message still Defective speed sensor.
Turn ignition ON.
appearing on the HMI? Replace motor.

Yes

Place the jumper between pin

H and pin K on the speed
Turn ignition OFF.
sensor interface on the
traction inverter.

Turn ignition ON

Continued on next page

313
Troubleshooting

Continued from previous page

No
Is the error message still Defective harness.
appearing on the HMI? Replace harness.

Yes

Turn ignition OFF.

Place the jumper between pin

J and K on connector C3 on
the traction inverter.

Turn ignition ON

No
Is the error message still Defective traction inverter.
appearing on the HMI? Replace traction inverter.

Yes

Refer to analog HVIL investigation

subtree.

314
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. 3) Replace traction inverter.

3) Traction inverter internal

failure.

The Traction inverter has its own internal interlock

system which detects if a connector on the motor or
traction inverter is unplugged. If a discontinuity is
detected between the traction inverter and motor, the
traction inverter raises fault reason 2. If a
discontinuity is detected on the traction inverter LV
side, the traction inverter raises fault reason 3.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

Connector C3

315
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.

Defective connector.
Replace the connector as described in the
“Wire Harness Connector Identification,
Location, and Service Chart” in the
Yes
Is there any connector Service Manual.
integrity issue?

Reconnect connector C3 to
the traction inverter.

No Turn ignition ON.

Is the error No
Defective traction inverter. message still
Complete.
Replace traction inverter. appearing on the
Yes
HMI?

316
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. troubleshooting guide.

Propulsion System faults may also be

investigated and resolved using the ODIN
tool and the TM4 SUMO Powertrain
Troubleshooting Guide.

HMI displays or logs

Fault code F0100 and
Traction inverter fault reason 4

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Check that the traction inverter

cover is properly installed on the
traction inverter as per the TM4
installation instructions.

Is the Refer to the ‘’Internal HVIL

Yes
traction inverter connection fault’’ tree in TM4
cover installed traction inverter troubleshooting
properly? guide.

Install the traction inverter

cover as per the instructions
provided in the TM4
installation manual.

317
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.
2) ESS fault.
3) Refer to traction inverter
3) Causes covered in traction troubleshooting guide.
inverter troubleshooting guide.

This is a warning message for the driver indicating 100% or if a limitation is requested by the BMS or
that the normal level of regenerative braking is not traction inverter for various other reasons.
available while cruise control is active. The driver
therefore may need to use the air brakes to slow the This message may be raised due to adverse driving
vehicle. conditions such as a prolonged downhill. It does not
necessarily indicate a problem with the vehicle.
Regenerative braking will be reduced if the state of
charge (SOC) of the high voltage batteries is close to

318
Troubleshooting

HMI displays or logs

Fault code F0102

Was this error raised at Yes

high SOC on high voltage Complete
batteries?

Yes
Does the HMI display Refer to the F0026 troubleshooting
F0026? tree.

Yes 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.

319
Troubleshooting

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.

320
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. harness.
2) Replace accelerator pedal.
2) Accelerator pedal internal
failure.

The accelerator pedal position is detected by two

sensors for redundancy. If the readings from the two
sensors do not match or at least one reading is out
of range, error F0104 will be raised.

Connector C655

Connector C651.A

321
Troubleshooting

Circuit73

Connector C651.B

322
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.

With a multimeter, check for continuity between the

following points:
AccPedal C655 VCU 651.A
Connector pin Connector pin
Pin 4 Pin 51

Pin 2 Pin 9

Pin 3 Pin 23
AccPedal C655 VCU 651.B
Connector pin Connector pin
Pin 1 Pin 7

Pin 5 Pin 5

Pin 6 Pin 23

- Continuity : Resistance is less than or equal to 2ohms.

Yes Is there any evidence No

Defective Harness Defective Acceleration Pedal.
of a continuity loss
Replace Harness. Replace Acceleration Pedal.
within the harness?

323
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.
3) Traction inverter internal
failure. 3) Replace Traction inverter.

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.

HMI displays “Traction

inverter No Contact”

Yes
Was error F0099 also Refer to the specific error
raised? troubleshooting tree.

Refer to the CAN investigation

subtree.
Investigate CAN B network.

Were you able to find a Yes

defect in the CAN A network Repair as per the subtree
causing this error to be instructions.
raised?

Defective traction inverter.

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0x07faff

Contact Dana for further

investigation.

328
Troubleshooting

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.

329
Troubleshooting

F0000 (Fault Reason 0x0afae0, 0x0afaf0)

Error Description Possible Causes Possible Solutions

iAPU has reported that the air 1) Air dryer cartridge in need of 1) Replace air dryer cartridge.
dryer cartridge is due for replacement.
replacement. 2) Contact Dana.
2) iAPU internal failure.

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0x0afaf0/0x0afae0

Turn ignition OFF.

Replace the cartridge as per the

Bendix maintenance manual
instructions.

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 No
message raised again
Complete
shortly after replacing the
cartridge?

Yes

Contact Dana for further

investigation.

330
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.

331
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0x233302

Check the air brake compressor oil

level.

Is the air brake No Contact Dana for further

compressor oil level
investigation.
low?

Yes

Check for oil leaks on and Yes Repair the leak according to the
Could you find any oil
around the air brake Bendix maintenance manual
leak?
compressor. instructions.

Refill the oil tank according to

Bendix maintenance manual
instructions.

Turn ignition ON.

Is the error still Yes Contact Dana for further

occurring on further
investigation.
key ON cycles?

Complete

332
Troubleshooting

F0000 (Fault Reason 0x233608, 0x233708, 0x233808)

Error Description Possible Causes Possible Solutions

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.

339
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0xa4f8f2

Check the air brake compressor oil

level.

Is the air brake No Contact Dana for further

compressor oil level
investigation.
low?

Yes

Check for oil leaks on and Yes Repair the leaks according to the
Could you find any oil
around the air brake Bendix maintenance manual
leaks?
compressor. instructions.

Refill the oil tank according to

Bendix maintenance manual
instructions.

Turn ignition ON.

Is the error still Yes Contact Dana for further

occurring on further
investigation.
key ON cycles?

Complete

340
Troubleshooting

F0000 (Fault Reason 0xa4f8ff)

Error Description Possible Causes Possible Solutions

iAPU has reported that the air 1) Air brake compressor oil 1) Change oil in air brake
brake compressor is due for an oil change needed. compressor per
change. manufacturer’s instructions.

HMI displays or logs

Fault code F0000 and
Air Brake DTC 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 No

Complete
again?

Yes

Contact Dana for further

investigation.

341
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. 2) Replace air brake compressor.

342
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 No
eventually raised Complete
again?

Yes

Refer to the cooling investigation

subtree.

Were you able to find a Yes Repair the defect as per the
defect within the cooling instructions in the
circuit? investigation subtree.

Yes No
Defective air brake compressor. Is the error eventually
Complete
Replace air brake compressor. raised again?

343
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.

344
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.

No
Is the error eventually
Complete
raised again?

Yes

Refer to the cooling investigation

subtree.

Were you able to find a Yes Repair the defect as per the
defect within the cooling instruction in the
circuit? investigation subtree.

Yes No
Defective air brake compressor. Is the error eventually
Complete
Replace air brake compressor. raised again?

345
Troubleshooting

F0000 (Fault Reason 0xa7f8ec)

Error Description Possible Causes Possible Solutions

iAPU has reported an error in CAN 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.

346
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0xa7f8ec

Does the HMI also Yes

Refer to the Air Dryer No contact
display “Air Dryer No
troubleshooting tree.
contact”?

Does the HMI also Yes

display “Brake Refer to the Brake Compressor No
Compressor No contact troubleshooting tree.
contact”?

Refer to CAN investigation subtree

Investigate CAN A network.
Complete

Were you able to find a Yes Take the actions Is the error code still
problem in the CAN A
prescribed in the subtree. displayed?
network?

No Yes

Contact Dana for further

investigation.

347
Troubleshooting

F0000 (Fault Reason 0xcef9f0, 0xd1f9ef, 0xdcf9f0, 0xddf9f0, 0xdef9f0)

Error Description Possible Causes 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 2) iAPU internal failure. pressure.
level.
2) Contact Dana.

348
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0xcef9f0/0xd1f9ef/
0xdcf9f0/0xddf9f0/0xdef9f0

Turn ignition OFF.

Measure and observe the air tank

pressures.

Reduce the air pressure in the air

tanks below 9 bar.

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.

Yes
Does the error code Contact Dana for further
appear again? investigation.

Complete

349
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.
2) iAPU internal failure.
2) Replace iAPU.

350
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 Yes

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
tank.

Replace iAPU dryer cartridge

according to the Bendix
maintenance manual instructions.

Using the Bendix service tool reset

the state of the cartridge in the
iAPU software.

Is the same error Yes

message being raised Defective iAPU.
again after operating the Replace iAPU.
truck for a while?

Complete
351
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.

352
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0xd9f9e2

Turn ignition OFF.

Measure and observe the air tank

pressures, the service brake and the
suspension circuits.

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.

Yes
Does the error code Contact Dana for further
appear again? investigation.

Complete
353
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.

354
Troubleshooting

HMI displays or logs

Fault code F0000 and
Air Brake DTC 0xdaf9e2

Turn ignition OFF.

Measure and observe the air tank

pressures, the service brake and the
suspension circuits.

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.

Yes
Does the error code Contact Dana for further
appear again? investigation.

Complete

355
Troubleshooting

F0000 (Fault Reason 0xfef9ff)

Error Description Possible Causes Possible Solutions

Service mode has been activated 1) Service mode active. 1) Clear error using Bendix
on the iAPU. service tool.

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 No

Complete
occur again?

Yes

Contact Dana for further

investigation.

356
Troubleshooting

F0001 - Please replace air dryer filter

Error Description Possible Causes Possible Solutions

Air dryer cartridge is due for 1) Air dryer cartridge in need of 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 No

Complete
again?

Yes

Fault code F0002 and
Air Brake DTC 0x03faff

Defective iAPU.
Replace iAPU.

360
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.

361
Troubleshooting

HMI displays or logs

Fault code F0002 and
Air Brake DTC 0x04f9e2

Does the HMI also Yes

Refer to the Air Dryer No contact
display “Air Dryer No
troubleshooting tree.
contact”?

Does the HMI also Yes

display “Brake Refer to the Brake Compressor No
Compressor No contact troubleshooting tree.
contact”?

Refer to CAN investigation subtree

Investigate CAN A network
Complete

Were you able to find a Yes Take the actions Is the error code still
problem in the CAN A
prescribed in the subtree. displayed?
network?

No Yes

Contact Dana for further

investigation.

362
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

No Install new port plug into port 41

Is iAPU pneumatic port 41
according to Bendix installation
plugged off?
manual.

Defective iAPU.
Replace iAPU.

363
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.

364
Troubleshooting

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.

365
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. 3) Replace HV fuse F4.

3) Blown HV fuse F4.

3
4

Connector C795
Connector C790

366
Troubleshooting

HMI displays or logs

Fault code F0002 and
Air Brake DTC 0x232802

Does the HMI also Yes 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.

Disconnect connector C795 from

High Voltage junction box.
Disconnect connector C790 from
air brake compressor.

Refer to the connector

investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

No
Continued on next page

367
Troubleshooting

No Continued from previous page

With a multimeter, check for continuity between the

following points:
HV JB C795P Air Brake Compressor C790S
Connector pin Connector pin

Pin 1 Pin 2

HV JB C795P Air Brake Compressor C790S

Connector pin Connector pin

Pin 2 Pin 1

- Continuity : Resistance is less than or equal to 2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

WARNING: Electrical hazard. Observing proper safety

precautions, open the HV
Follow Safety Warnings and High junction box.
Voltage Shutdown Procedures
defined in the 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 Yes
intermittent?

WARNING: Electrical hazard.

No
The High Voltage junction box
cover and all HV connections
must be re installed properly
Contact Dana for further after replacing the fuse and
investigation. before restarting the truck.

368
Troubleshooting

F0002 (Fault Reason 0x232B01)

Error Description Possible Causes Possible Solutions

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.

369
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 Yes Refer to the corresponding

F0017 or F0026? troubleshooting tree.

Defective air brake compressor.

Replace air brake compressor.

370
Troubleshooting

F0002 (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.

371
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.

372
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.

No
Is the error eventually
Complete
raised again?

Yes

Refer to the cooling investigation

subtree.

Yes Repair the defect as per the

Was a defect found in
instruction in the
the cooling circuit?
investigation subtree.

Yes No
Defective air brake compressor. Is the error eventually
Complete
Replace air brake compressor. raised again?

373
Troubleshooting

F0002 (Fault Reason 0x234209)

Error Description Possible Causes Possible Solutions

Air brake compressor has reported 1) Software or internal air brake 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

further investigation.

374
Troubleshooting

F0002 (Fault Reason 0x234309, 0x234409, 0x234509)

Error Description Possible Causes Possible Solutions

Air brake compressor has reported 1) Connector C790 unplugged or 1) Plug in connector or replace
a discontinuity in the high voltage defective. HV harness.
interlock loop (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). If this connector is
unplugged, the HVIL will be open and the air brake
compressor will send an error message via CAN.

The air brake compressor is also connected to the

analog HVIL, which is a physical circuit that runs
through various HV connectors on the vehicle. If a
connector is unplugged unsafely, the HVIL will be
broken and the VCU will detect the loss of signal
voltage on the circuit.

Connector C790

375
Troubleshooting

HMI displays or logs

Fault code F0002 and Air brake DTC 0x234309
Fault code F0002 and Air brake DTC 0x234409
Fault code F0002 and Air brake DTC 0x234509

Yes No
Does the HMI also display Contact Dana for further
F0140? investigation.

Does the HMI also display Yes Refer to the Analog HVIL
F0063/F0062/F0061? investigation subtree.

Could you find any defect in Yes Repair as prescribed

the HVIL analog circuit? in the subtree.

WARNING: Electrical hazard.

No
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

376
Troubleshooting

Continued from previous page

Disconnect connector C790

from the air brake
compressor.

Refer to the connector

investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

With a multimeter, check for continuity between the following

points:
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.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Contact Dana for further

investigation.

377
Troubleshooting

F0002 (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.

378
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.

379
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.

380
Troubleshooting

F0002 (Fault Reason 0x4ff8e4)

Error Description Possible Causes Possible Solutions

iAPU has reported that its supply 1) DCDC or LV distribution fault. 1) Troubleshoot specific error.
voltage is out of range.
2) Blown 24V fuse F2. 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)

381
Troubleshooting

HMI displays or logs

Fault code F0002 and
Air brake DTC 0x4ff8e4

Does the HMI also display Yes 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.

Defective connector.
Is there any problem with Replace the connector as described in the “Wire
the connector integrity? Yes Harness Connector Identification, Location, and
Service Chart” in the Service Manual

With an multimeter, measure the voltage between

the following points:
iAPU C203S Ground C101
Connector pin Connector pin

Pin 2 Pin 5

Continued on next page

382
Troubleshooting

Continued from previous page

Is the voltage
Defective iAPU.
measurement between
Yes Replace iAPU.
16V – 32V?

Inspect fuse F2 on 24V fuse box

C20.

Is fuse F2 on 24V fuse

box C20 blown or
intermittent ? Yes
A

Turn ignition OFF.

Disconnect connector C40 and

C367.

Refer to the connector

investigation subtree.

Continued on next page

383
Troubleshooting

Continued from previous page

Remove fuse F2 in order to take

continuity measures from inside
the fuse box.

With a multimeter, check for continuity between the

following points:
C40S 24V fuse box C20
Connector pin Terminal

Pin 2 A2
C40P C367S
Connector pin Connector pin

Pin 2 Pin 2

C367S iAPU C203

Connector pin Connector pin

Pin 2 Pin 2

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Contact Dana for further

investigation.

384
Troubleshooting

Complete

A
No

Replace fuse F2 on 24V fuse box C20. Does fuse F2 blow again
Restart the vehicle. during a test drive?

Yes

Disconnect connector C202

Refer to the connector Turn ignition OFF and disconnect
from the air brake
investigation subtree. fuse F2 from 24V fuse box C20.
compressor.

Defective connector.
Is there any problem with Replace the connector as described in the “Wire Harness
the connector integrity? Yes Connector Identification, Location, and Service Chart” in the
Service Manual.

With a multimeter, check for short circuit between the

following points:
24V fuse box C20 Ground
Terminal
Is there any Yes Defective harness.
A2 Ground Strip 1 evidence of a short
Replace harness.
circuit?
-LV short: Resistance measurement is less than 100k-
ohms.
-Inspect all connectors and wires between the two test
No
points of the harness ends.

Replace F2 on 24V fuse box C20.

Restart the vehicle.

Does fuse F2 blow again

Complete
No during a test drive?

Yes

Contact Dana for further

investigation.

385
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. Follow
the instructions provided by Bendix.

386
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. 3) Replace HV fuse F4.

3) Blown HV fuse F4.

3
4

Connector C795
Connector C790

387
Troubleshooting

HMI displays or logs

Fault code F0002 and
Air brake DTC 0xa1f8e2

Does the HMI also display Yes 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.

Disconnect connector C795 from

air brake compressor.
Disconnect connector C790 from
HV junction box.

Refer to the connector

investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

No
Continued on next page

388
Troubleshooting

No Continued from previous page

With a multimeter, check for continuity between the

following points:
Air Brake Compressor C790P HV Jct Box C795S
Connector pin Connector pin

Pin 1 Pin 2

Air Brake Compressor C790P HV Jct Box C795S

Connector pin Connector pin
Pin 2 Pin 1

- Continuity : Resistance is less than or equal to 2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

No
Observing proper safety
Inspect fuse F4 in the HV
precautions, open the HV
junction box.
junction box.

Contact Dana for further No Is fuse F4 blown or

investigation. intermittent?

Yes

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.

389
Troubleshooting

F0002 (Fault Reason 0xa2f8ec)

Error Description 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.

390
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. failure. 2) Replace air brake compressor.

HMI displays or logs

Fault code F0002 and
Air brake DTC 0xa5f8e0

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.

No
Is the error eventually
Complete
raised again?

Yes

Refer to the cooling investigation

subtree.

Were you able to find a Yes Repair the defect as per the
defect within the cooling instruction in the
circuit? investigation subtree.

Yes No
Defective air brake compressor. Is the error eventually
Complete
Replace air brake compressor. raised again?

391
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

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.

No
Is the error eventually
Complete
raised again?

Yes

Refer to the cooling investigation

subtree.

Were you able to find a Yes Repair the defect as per the
defect within the cooling instruction in the
circuit? investigation subtree.

No
Defective air brake compressor. Is the error eventually
Complete
Replace air brake compressor. raised again?
Yes

392
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.

393
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.

No
Is the primary circuit Defective iAPU.
pressure less than 4.8bar? Replace iAPU.

Yes

Check that the air brake

compressor is running.

No Are any error messages No

Is the air brake related to the air brake Defective air brake compressor.
compressor running? compressor being raised on Replace air brake compressor.
the HMI?

Yes
Yes

Inspect the primary circuit Refer to the specific error

and air tank for leaks. troubleshooting tree.

Continued on next page

394
Troubleshooting

Continued from previous page

No
Are there any leaks in Inspect the iAPU for air
the primary circuit? leaks.

Yes

Repair any air leaks and Yes No

Are there any air Defective iAPU.
refill the air tanks by
leaks? Replace iAPU.
turning ignition ON.

Is the same error message Yes

Defective iAPU.
being raised again on next
Replace iAPU.
ignition cycle?

Complete

395
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.

396
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.

No
Is the secondary circuit Defective iAPU.
pressure less than 4.8bar? Replace iAPU.

Yes

Check that the air brake

compressor is running.

No Are any error messages No

Is the air brake related to the air brake Defective air brake compressor.
compressor running? compressor being raised on Replace air brake compressor.
the HMI?

Yes
Yes

Inspect the secondary circuit Refer to the specific error

and air tank for leaks. troubleshooting tree.

Continued on next page

397
Troubleshooting

Continued from previous page

No
Are there any leaks in Inspect the iAPU for air
the secondary circuit? leaks.

Yes

Repair any air leaks and Yes No

Are there any air Defective iAPU.
refill the air tanks by
leaks? Replace iAPU.
turning ignition ON.

Is the same error message Yes

Defective iAPU.
being raised again on next
Replace iAPU.
ignition cycle?

Complete

398
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

No
Are air pressures in both Deplete the pressure in both air
air tanks less than 4 bar? tanks to less than 4 bar.

Yes

Put the truck in ready mode and

allow air brake compressor to fill
both tanks to cut off pressure.

Allow air brake to run and fill the system.

Wait at least 1 minute after filling.

Yes
Is the DTC still displayed Defective iAPU.
on the HMI? Replace iAPU.

Complete

399
Troubleshooting

F0002 (Fault Reason 0xe2f9e4)

Error Description Possible Causes Possible Solutions

iAPU has reported low air pressure 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

investigation.

400
Troubleshooting

F0002 (Fault Reason 0xe3f9e4)

Error Description Possible Causes Possible Solutions

iAPU has reported low air pressure 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

investigation.

401
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.
Replace iAPU.

402
Troubleshooting

F0140 - Potential High Voltage Hazard! Brake compressor HVIL Fault

Error Description Possible Causes Possible Solutions

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. The
distribution being safely ended. The air brake connector may be unplugged or there may be a loss
compressor monitors continuity between the HVIL of continuity between its HVIL pins.
pins on its HV connector (C790). If this connector is
unplugged, the HVIL will be broken and the air brake
compressor will send an error message via CAN.

The air brake compressor is also connected to the

If one of the analog HVIL errors (F0061, F0062, or

F0063) is raised, the problem is probably an
unplugged connector or other discontinuity
elsewhere on the analog HVIL. The technician
should refer to the analog HVIL troubleshooting Connector C790
subtree to locate the problem.

403
Troubleshooting

HMI displays or logs

Fault code F0140

Does the HMI also display Yes Refer to the Analog HVIL
F0063/F0062/F0061? investigation subtree.

Could you find any defect in Yes Repair as prescribed

the HVIL analog circuit? in the in subtree.

WARNING: Electrical hazard.

No
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

404
Troubleshooting

Continued from previous page

Disconnect connector C790

from the air brake
compressor.

Refer to the connector

investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

With a multimeter, check for continuity between the following

points:
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.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Contact Dana for further

investigation.

405
Troubleshooting

Air Brake Compressor no contact

Error Description Possible Causes Possible Solutions

VCU has not received any CAN 1) Blown 24V fuse F2. 1) Replace 24V fuse F2.
message from the air brake
compressor within a specified time 2) Loss of continuity caused by 2) Replace LV connector or
interval. defective LV harness or harness per Service Manual.
connector.
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.

Connector C203

Connector C202

406
Troubleshooting

HMI displays
“Brake compressor No contact.”

Turn ignition OFF.

Inspect fuse F2 in the 24V fuse

box C20.

A
Is fuse F2 blown or Yes
intermittent?

Disconnect connector C202 from

air brake compressor.

Refer to the connector

investigation subtree.

Continued on next page

407
Troubleshooting

Continued from previous page

Defective connector.
Yes Replace the connector as described in the
Is there any problem with
“Wire Harness Connector Identification,
the connector integrity?
Location, and Service Chart” in the Service
Manual

Remove fuse F2 in order to take

continuity measures from inside
the firebox.

With a multimeter, check for continuity between the

following points:
Air brake Compressor C202S 24V fuse box C20
Connector pin Terminal

Pin 1 A2

Pin 6 A2

Air brake Compressor C202S

Ground
Connector pin
Pin 5 Ground

- Continuity : Resistance is less than or equal to 2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN Investigation

subtree.
Investigate CAN A network.

Contact Dana for further Yes No

Is the error still raised? Complete
investigation.

408
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 No

Complete
during a test drive?

Yes

Disconnect fuse F2 from 24V

fuse box C20.

Disconnect connector C202 from

air brake compressor.
Disconnect connector C203 from
iAPU.

Refer to the connector

investigation subtree.

No
Continued on next page

409
Troubleshooting

No Continued from previous page

With a multimeter, check for short circuit between the

following points:
Air brake Compressor C202S
Connector pin Ground

Pin 1 Ground

Pin 6 Ground

iAPU C203S
Ground
Connector pin

Pin 2 Ground

-LV short: Resistance measurement is less than 100k-ohms.

-Inspect all connectors and wires between the two test
points of the harness ends.

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Contact Dana for further

investigation.

410
Troubleshooting

Air Dryer No Contact

Error Description Possible Causes Possible Solutions

VCU has not received any CAN 1) Blown 24V fuse F2. 1) Replace 24V fuse F2.
message from the iAPU within a
specified time interval. 2) Blown 12V fuse F9. 2) Replace 12V fuse F9.

3) Loss of continuity caused by 3) Replace LV connector or

defective LV harness or harness per Service Manual.
connector.
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.

Connector C204

Connector C202

Connector C203

Connector C206

411
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?
Yes
A

Disconnect connectors C203,

C204, and C206 from iAPU.

Continued on next page

412
Troubleshooting

Continued from previous page

Refer to the connector

investigation subtree.

No
Remove fuse F2 in order to take
continuity measures from inside
the fuse box.

With a multimeter, check for continuity between the

following points:
iAPU C203S 24V fuse box C20
Connector pin Terminal

Pin 2 A2

iAPU C203S
Ground
Connector pin
Pin 1 Ground

iAPU C204S 12V fuse box C14

Connector pin Terminal
Pin 1 A9

iAPU C206S 12V fuse box C14

Connector pin Terminal
Pin 1 A9

iAPU C206S
Ground
Connector pin
Pin 2 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

413
Troubleshooting

Continued from previous page

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN Investigation

subtree.
Investigate CAN A network.

No
Is the error still raised? Complete

Yes

Contact Dana for further

investigation.

414
Troubleshooting

Disconnect blown fuse F2 from

24V fuse box C20.

Replace fuse F2 on 24V fuse box

C20.
Restart the vehicle.

No
Does fuse F2 blow again? Complete

Yes

Turn ignition OFF and

disconnect F2 from 24V fuse box
C20.

Disconnect connector C202 from

air brake compressor.
Disconnect connector C203 from
iAPU.

Refer to the connector

investigation subtree.

No
Continued on next page

415
Troubleshooting

No Continued from previous page

With a multimeter, check for short circuit between the

following points:
Air brake Compressor C202S
Ground
Connector pin

Pin 1 Ground

Pin 6 Ground

iAPU C203S
Ground
Connector pin

Pin 2 Ground

-LV short: Resistance measurement is less than 100k-ohms.

-Inspect all connectors and wires between the two test points
of the harness ends.

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Contact Dana for further

investigation.

416
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. The
and 24V equipment throughout the vehicle. 24V output from the DCDC is used to charge the two
low voltage batteries. The DCDC is connected to the
Component Descriptions cooling circuit to help maintain the proper operating
temperature.
DCDC

The DCDC converts 650V DC input supplied by the

ESS to 24V DC output. It consists of a power stage,

417
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.

4) Loss of continuity caused by 4) Replace HV harness.

defective HV harness or
connector.

3 4

Connector 730

3
4

Connector C712

418
Troubleshooting

HMI displays or logs

Fault code F0008 and
DCDC fault reason 1

Does the HMI Yes Refer to error F0026

also display error troubleshooting tree.
F0026?

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

No
Wait 30 seconds.

Put the vehicle in ready mode.

Does the error occur No Potential compatibility issue

Wait 30 seconds.
again? with aftermarket accessories.

Yes

Does the error occur Yes

Turn ignition OFF.
again?

Complete. If error occurs again,

continue with the next steps.
Continued on next page

419
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. Yes Is there any problem with

Replace harness. the connector integrity?

With a multimeter, check for continuity between the

following points:
DCDC C730P HV Jct Box C712P
Connector pin Connector pin

Pin 1 Pin 2

DCDC C730P HV Jct Box C712P

Connector pin Connector pin
Pin 2 Pin 1

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

420
Troubleshooting

Continued from previous page

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Connect connector C712 to HV

junction box.

Observing proper safety

precautions, open the HV
junction box.

Inspect fuse F8 in the HV

junction box.

No
Is fuse F8 blown or Contact Dana for further
intermittent? investigation.

Yes

Replace fuse F8.

DANA must always be informed
whenever replacing a fuse in the
HV junction box before
restarting the truck.

421
Troubleshooting

F0008 (Fault Reason 2)

Error Description Possible Causes Possible Solutions

DCDC has detected that the 1) Compatibility problem with 1) Disconnect incompatible
DCDC input voltage is too high. aftermarket accessory. accessory.

2) ESS fault. 2) Troubleshoot specific error.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 2

Check the HMI for other faults.

Does the HMI also Yes Refer to error F0026

display error F0026? troubleshooting tree.

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Does the error occur No Potential compatibility issue

again? with aftermarket accessories.

Yes

Contact Dana for further

investigation.

422
Troubleshooting

F0008 (Fault Reason 3)

Error Description Possible Causes Possible Solutions

DCDC has detected that the 1) Compatibility problem with 1) Disconnect incompatible
DCDC output voltage is too low. aftermarket accessory. accessory.

2) At least one low voltage 2) Replace low voltage battery or

battery defective, not to spec, repair battery wiring.
or wired incorrectly.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 3

Are any
aftermarket Yes Disconnect all aftermarket
accessories accessories and put the vehicle
installed on the in ready mode.
vehicle?

Does the error still No Potential compatibility issue

appear? with aftermarket accessories.

Yes

Put the vehicle in ready mode

Turn ignition OFF.
and start a stopwatch.

Does the error

Does the error
No disappear more Yes
disappear between 3
than 5 minutes
and 5 minutes after
after entering
entering ready mode?
ready mode?
Complete. If error occurs again
No later, continue with the next steps.
Yes

A Contact Dana for further

investigation.

423
Troubleshooting

A Inspect the LV batteries.

Are both batteries Replace faulty battery with a

No
the correct voltage battery that fits the system
(12V) and specifications.
specification?

Yes

With a multimeter, measure the voltage between the

following points:
LV Battery 1 LV Battery 1
Negative terminal Positive terminal

- +

LV Battery 2 LV Battery 2
Negative terminal Positive terminal

- +

Is the voltage across No Replace faulty battery with a

each battery battery that fits the system
12V? specifications.

Yes

With a multimeter, measure the voltage between the

following points:
LV Battery 1 LV Battery 2
Negative terminal Positive terminal

- +

Continued on next page

424
Troubleshooting

Continued from previous page

Is the voltage Yes Contact Dana for further

24V? investigation.

Inspect the battery wiring.

Is the negative
Incorrect wiring.
terminal on battery 2 No Wire the batteries according to
wired to the positive
the instructions provided by the
terminal on
installation manual.
battery 1?

Yes

Disconnect connector RT019 from 12V

battery 2.
Disconnect connector RT020 from 12V
battery 1.

Refer to connector investigation

subtree.

Is there any Defective connector.

problem with the Yes Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No
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.

Yes
Is there any evidence Defective cable.
of continuity loss? Replace cable.

Contact Dana for further

investigation.
425
Troubleshooting

F0008 (Fault Reason 4)

Error Description Possible Causes Possible Solutions

DCDC has detected that the 1) Compatibility problem with 1) Disconnect incompatible
DCDC output voltage is too high. aftermarket accessory. accessory.

2) At least one low voltage 2) Replace low voltage battery or

battery defective, not to spec, repair battery wiring.
or wired incorrectly.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 4

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Does the error still No Potential compatibility issue

appear? with aftermarket accessories.

Yes

Inspect the LV batteries. Turn ignition OFF.

Are both batteries the No Replace faulty battery with a

correct voltage (12V) battery that fits the system
and specification? specifications.

Yes

Contact Dana for further

investigation.

426
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. power steering load returns to
normal.
3) Short circuit in LV harness or
connector. 3) Replace LV connector or
harness per Service Manual.

427
Troubleshooting

HMI displays or logs

Fault code F0008 and
DCDC fault reason 5

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Connect the vehicle to a Yes Does the error still No Potential compatibility issue
charger. appear? with aftermarket accessories.

Does the error still No Refer to error F0010

appear? troubleshooting tree.

Yes With a multimeter, check for short circuit between the

following points:

RT008 DCDC
Ground
Screw terminal
RT008 Ground
WARNING: Electrical hazard.

Follow Safety Warnings and High -LV short: Resistance measurement is less than 100k-ohms.
Voltage Shutdown Procedures -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 Yes

Defective harness.
Disconnect screw terminal of a short circuit within the
Replace harness.
RT008 from the DCDC. harness?

No
Contact Dana for further
investigation.

428
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.

429
Troubleshooting

F0008 (Fault Reason 7)

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.

430
Troubleshooting

F0008 (Fault Reason 8)

Error Description Possible Causes Possible Solutions

DCDC has detected a 1) CAN communication problem. 1) Resolve CAN communication

communication failure on the 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.

No
Is the error still raised? Complete

Yes

Contact Dana for further

investigation.

431
Troubleshooting

F0008 (Fault Reason 9)

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.

432
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. power steering load returns to
normal.
3) Short circuit in LV harness or
connector. 3) Replace LV connector or
harness per Service Manual.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 10

Refer to error F0008

(DCDC Fault Reason 5)
troubleshooting tree.

433
Troubleshooting

F0008 (Fault Reason 11)

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.

434
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. power steering load returns to
normal.
3) Short circuit in LV harness or
connector. 3) Replace LV connector or
harness per Service Manual.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 12

Refer to error F0008

(DCDC Fault Reason 5)
troubleshooting tree.

435
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.
or wired incorrectly.

This error indicates that the DCDC has disabled its

LV output because it detected that the output voltage Troubleshooting for this error is the same as for
is too high. The DCDC will take this action if it F0008 (DCDC Fault Reason 4).
detects that the output voltage is greater than 32 V.

HMI displays or logs

Fault code F0008 and
DCDC fault reason 13

Refer to error F0008

(DCDC Fault Reason 4)
troubleshooting tree.

436
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.
or wired incorrectly.

437
Troubleshooting

HMI displays or logs

Fault code F0008 and
DCDC fault reason 14

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Does the error still No Potential compatibility issue

appear? with aftermarket accessories.

Yes
Turn ignition OFF.

Are both batteries the No Replace faulty battery with a

Inspect the LV batteries. correct voltage (12V) battery that fits the system
and specification? specifications.

Yes

With a multimeter, measure the voltage between the

following points:
LV Battery 1 LV Battery 1
Negative terminal Positive terminal

- +

LV Battery 2 LV Battery 2
Negative terminal Positive terminal

- +

Continued on next page

438
Troubleshooting

Continued from previous page

Is the voltage across No Replace faulty battery with a

each battery battery that fits the system
12V? specifications.

Yes

With a multimeter, measure the voltage between the

following points:
LV Battery 1 LV Battery 2
Negative terminal Positive terminal

- +

Is the voltage
24V?
No
A
Yes

Inspect the battery wiring.

The positive terminal on battery

2 should be wired to the DCDC Incorrect wiring.
output RT008. Wire the batteries according to
the instructions provided by the
The negative terminal on battery installation manual.
1 should be wired to the chassis
ground.
No
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. Yes

Contact Dana for further

investigation.

439
Troubleshooting

Inspect the battery wiring.

Is the negative Incorrect wiring.

terminal on battery 2 No Wire the batteries according to
wired to the positive the instructions provided by the
terminal on battery installation manual.
1?

Yes

Disconnect connector RT019

from 12V battery 2.
Disconnect connector RT020
from 12V battery 1.

Refer to connector investigation

subtree.

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.

Yes
Is there any evidence of Defective cable.
continuity loss? Replace cable.

Contact Dana for further

investigation.
440
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.
or wired incorrectly.
3) Replace LV connector or
3) Defective LV harness between harness per Service Manual.
DCDC and VCU.

441
Troubleshooting

HMI displays or logs

Fault code F0008 and
DCDC fault reason 15

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Does the error still No Potential compatibility issue

appear? with aftermarket accessories.

Yes
Check the HMI for other faults.

Does the HMI also Yes Refer to error F0008 (DCDC fault
display F0008 (DCDC
reason 3) troubleshooting tree.
fault reason 3)?

Does the HMI also Yes Refer to error F0008 (DCDC fault
display F0008 (DCDC
reason 4) troubleshooting tree.
fault reason 4)?

Turn ignition OFF.

Continued on next page

442
Troubleshooting

Continued from previous page

Inspect the LV batteries.

VCU C651.B
12V fuse box C14 A5
Connector pin
A5 Pin 73

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Contact Dana for further

investigation.
444
Troubleshooting

Inspect the battery wiring.

Is the negative Incorrect wiring.

terminal on battery 2 No Wire the batteries according to
wired to the positive the instructions provided by the
terminal on battery installation manual.
1?

Yes

Disconnect connector RT019

from 12V battery 2.
Disconnect connector RT020
from 12V battery 1.

Refer to connector investigation subtree.

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.

Yes
Is there any evidence of Defective cable.
continuity loss? Replace cable.

Contact Dana for further

investigation.
445
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.
or wired incorrectly.
3) Replace LV connector or
3) Defective LV harness between harness per Service Manual.
DCDC and EHPS motor
controller.

446
Troubleshooting

HMI displays or logs

Fault code F0008 and
DCDC fault reason 16

Are any aftermarket Yes Disconnect all aftermarket

accessories installed accessories and put the vehicle
on the vehicle? in ready mode.

Does the error still No Potential compatibility issue

appear? with aftermarket accessories.

Yes
Check the HMI for other faults.

Does the HMI also Yes Refer to error F0008 (DCDC fault
display F0008 (DCDC
reason 3) troubleshooting tree.
fault reason 3)?

Does the HMI also Yes Refer to error F0008 (DCDC fault
display F0008 (DCDC
reason 4) troubleshooting tree.
fault reason 4)?

Turn ignition OFF.

Continued on next page

447
Troubleshooting

Continued from previous page

Inspect the LV batteries.

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 Yes Defective harness.

continuity loss? Replace harness.

Contact Dana for further

investigation.
449
Troubleshooting

Inspect the battery wiring.

Is the negative Incorrect wiring.

terminal on battery 2 No Wire the batteries according to
wired to the positive the instructions provided by the
terminal on battery installation manual.
1?
Yes

Disconnect connector RT019

from 12V battery 2.
Disconnect connector RT020
from 12V battery 1.

Refer to connector investigation subtree.

No
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.

Yes
Is there any evidence of Defective cable.
continuity loss? Replace cable.

Contact Dana for further

investigation.
450
Troubleshooting

F0009 - 12V/24V Charging System Fault

Error Description Possible Causes Possible Solutions

The DCDC has detected that its 1) Cooling system problem. 1) Resolve cooling system
internal temperature is too high. problem.

HMI displays or logs

Fault code F0009

Does the HMI also Yes Refer to the corresponding

display error F0059 or
troubleshooting tree.
F0060?

Does the HMI also

Yes Contact Dana for further
display error F0008
(DCDC fault reason investigation.
11)?

Refer to the cooling system

investigation subtree.

Yes
Was any root cause
identified in the Complete
cooling system?

No No

Disconnect the coolant hoses

Is the error still
from the DCDC and check that
raised?
the flow path is not obstructed.

Yes

Contact Dana for further

investigation.

451
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.
harness.

The purpose of the HVIL is to provide a warning if

any HV connector is unplugged without the HV
distribution being safely ended. The DCDC monitors
continuity between the HVIL pins on its HV
connector (C730). If this connector is unplugged
unsafely, the HVIL will be broken and the DCDC will
send an error message via CAN.

If error F0061, F0062, or F0063 also appears, it is

possible that connector C712 on the HV junction box
is disconnected or faulty.

3 4

Connector C730

4
3

Connector C712

452
Troubleshooting

HMI displays or logs

Fault code F0144

Does the HMI also

A
Yes
Check the HMI for other faults. display error F0061,
F0062, or F0063?

WARNING: Electrical hazard.

Follow Safety Warnings and High Turn ignition OFF.

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Inspect connector C730 on

DCDC.

Yes Is connector C730

Plug it in and restart the vehicle.
unplugged?

Disconnect connector C730 from

DCDC.

Continued on next page

453
Troubleshooting

Continued from previous page

Refer to connector
investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

With a multimeter, check for continuity between the

following points:
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 Yes Defective harness.

continuity loss? Replace harness.

Contact Dana for further

investigation.

454
Troubleshooting

A
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.

Yes Is connector C730 or

Plug it in and restart the vehicle.
C712 unplugged?

Disconnect connector C730 from

DCDC.
Disconnect connector C712 from
HV junction box.

Continued on next page

455
Troubleshooting

Continued from previous page

Refer to connector
investigation subtree.

Is there any problem with Yes Defective connector.

the connector integrity? Replace harness.

With a multimeter, check for continuity between the

following points:
DCDC C730P DCDC C730P
Connector pin Connector pin

Pin 3 Pin 4

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.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Contact Dana for further

investigation.

456
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.

3) Loss of continuity caused by 3) Replace LV connector or

defective LV harness or harness per Service Manual.
connector.
4) Resolve CAN communication
4) CAN communication problem. problem.

The DCDC also monitors CAN connectivity and will

raise its own error F0008 (DCDC fault reason 8) if it
detects a loss of communication. If this error
appears, it points to a problem with the CAN rather
than the DCDC power supply as the likely root
cause.

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.

Connector C84

457
Troubleshooting

HMI displays
“DCDC No contact.”

Does the HMI also Yes

Refer to error F0008 (DCDC fault
display error F0008
reason 8) troubleshooting tree.
(DCDC fault reason
8)?

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Inspect fuse F3 in the 24V fuse

box C20.
Is fuse F3 blown or
intermittent?
Yes
A

No
Inspect fuse F12 in the 24V fuse
box C20.

Disconnect connector C84 from

No DCDC.
Is fuse F12 blown or
Remove fuse F3 and F12 in order to
intermittent?
take continuity measures from
inside the fuse box.

Yes

Refer to connector

B investigation subtree.

Continued on next page

458
Troubleshooting

Continued from previous page

Yes 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
Connector pin Terminal

Pin 1 C2

DCDC C84 24V fuse box C20

Connector pin Terminal
Pin 7 A3

DCDC C84
Ground
Connector pin
Pin 2 Ground

Pin 3 Ground

Pin 4 Ground

Pin 8 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Refer to the CAN Investigation

subtree.
Investigate CAN D network.

Continued from previous page

459
Troubleshooting

Continued on next page

Is the error still being No

raised on further key ON Complete
cycles?

Yes

Contact Dana for further

investigation.

460
Troubleshooting

A
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 Yes

Disconnect connector C84 from
disconnect F3 from 24V fuse
DCDC.
box C20.

Refer to connector investigation subtree.

Continued on next page No

461
Troubleshooting

Continued from previous page

With a multimeter, check for short circuit between

the following points:
DCDC C84
Ground
Connector pin

Pin 7 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any
evidence of a short Yes Defective harness.
circuit within the Replace harness.
harness?

Replace fuse F3 on 24V fuse box

C20.
Restart the vehicle.

Did fuse F3 blow again No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

462
Troubleshooting

B 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 Yes

Disconnect connector C84 from
disconnect F12 from 24V fuse
DCDC.
box C20.

Refer to connector investigation subtree.

No
Continued on next page

463
Troubleshooting

No Continued from previous page

With a multimeter, check for short circuit between

the following points:
DCDC C84
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.

Is there any
evidence of a short Yes Defective harness.
circuit within the Replace harness.
harness?

Replace fuse F12 on 24V fuse

box C20.
Restart the vehicle.

Did fuse F12 blow again No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

464
Troubleshooting

Low Voltage Distribution System

The low voltage distribution system distributes 12V MPDM
and 24V power throughout the vehicle to power
onboard equipment and accessories. The Multiplex Power Distribution Module (MPDM)
provides a 12V output to power equipment
Component Descriptions throughout the vehicle. The MPDM outputs are fused
and in some cases are controlled by relays.
Low Voltage Batteries
12V Fusebox (C14)
The low voltage batteries are 12V batteries which
are used to power all LV onboard equipment. They The 12V fuse box provides a fused 12V output to
are connected in series to provide both 12V and 24V power equipment throughout the vehicle.
output as needed for the various equipment on the
vehicle. The batteries are charged by the DCDC. 24V Fusebox (C20)

Equalizer The 24V fuse box provides a fused 24V output to

power equipment throughout the vehicle.
The purpose of the equalizer is to maintain an equal
level of charge between the two low voltage batteries LOTO Switch
and to ensure the correct voltage is distributed on
the 12V and 24V networks. The lockout / tag-out (LOTO) switch is used to
disconnect the LV networks from the DCDC and low
voltage batteries during maintenance activities.

465
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. 3) Replace MPDM.

This error indicates that the MPDM has detected that

one of its fuses has blown. The MPDM provides 16 Troubleshooting for errors F0064 to F0079 is similar
fused 12V outputs, each with a corresponding error and a single generic troubleshooting tree is provided.
code. The fuses are numbered F1 through F16. The The specific fuse, relay, connector, and pin details
consequences of the error will depend on which fuse for each error code are provided in the table below.
is blown. The technician should use the table to look up the
information corresponding to the specific error code
The MPDM also monitors its internal relays and will and then use this information in the generic
raise the corresponding error F0080 through F0087 troubleshooting tree.
if it detects a failure. There may be some cross-
sensitivity between fuse and relay error detection.

Relay Fusebox
Fuse Error Error Fuse Relay Fusebox Connector Subsystem
Number Number Number Number Connector Pin Description Connector
F0064 F0080 Fuse F1 Relay K1 C11 D ESS_IGN C44
F0065 F0083 Fuse F2 Relay K4 C11 C ePTO_IGN C23
F0066 F0087 Fuse F3 Relay K7 C11 F CHILLER_IGN C45
F0067 F0081 Fuse F4 Relay K2 C11 B MCU_PWR C3
F0068 F0086 Fuse F5 Relay K8 C11 H MCU_IGN C3
F0069 F0085 Fuse F6 Relay K6 C11 G ESS_CHG_IGN C44
F0070 F0082 Fuse F7 Relay K3 C11 E OBC_IGN C22
F0071 F0084 Fuse F8 Relay K5 C11 A ESS_PWR C44
F0072 N/A Fuse F9 N/A C12 D FSVCU_PWR C54
F0073 N/A Fuse F10 N/A C12 C
F0074 N/A Fuse F11 N/A C12 G CHG_LED_PWR C53/C54
F0075 N/A Fuse F12 N/A C12 H OBC_PWR C22
F0076 N/A Fuse F13 N/A C12 E
F0077 N/A Fuse F14 N/A C12 F TELE_BATT_PWR C661
F0078 N/A Fuse F15 N/A C12 B
F0079 N/A Fuse F16 N/A C12 A MPDM_PWR C10

MPDM Table

466
Troubleshooting

Connector C12 (gray)

Connector C3

Connector C22

Connector C10

Connector C23

Connector C11 (black)

467
Troubleshooting

Connector C44

Connector C54

Connector C45

Connector C661

Connector C53

468
Troubleshooting

HMI displays or logs

Fault code F0064 to F0079.

Yes No
Are multiple powertrain
fuse error messages
displayed on the HMI?
Does the HMI also
display F0095 ? A
No
Yes

Refer to the MPDM Table to Refer to error F0095

determine which fuse to check. troubleshooting tree.

Perform a continuity check on

Turn ignition OFF. the fuse listed in the error
message.

Disconnect the low voltage Yes Is the suspect

connection as the device that is fuse blown or
associated with the blown fuse. intermittent?

Remove the blown fuse and

install a new fuse. Then turn on
ignition to ready mode.
Defective MPDM.
Replace the MDPM.

Turn ignition OFF.

Inspect the associated fuse.

Continued on next page

469
Troubleshooting

Continued from previous page

Did the fuse blow No Reconnect the harness to the device.

again? Turn ON the ignition to ready mode.

Yes

Turn the ignition OFF.

Inspect the associated fuse again.

Refer to the connector

investigation subtree.

Did the fuse blow No

Complete
again?

Yes

Defective device.
Replace the device associated with the
blown fuse.

Yes Defective connector.

Is there any problem
Replace the connector as described in the “Wire
with the connector
Harness Connector Identification, Location, and
integrity?
Service Chart” in the Service Manual

No
Continued on next page

470
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. Repeat the trouble tree steps.
-Inspect all connectors and wires between the two
test points of the harness ends.

Yes

Is there any evidence No Does the error still

of a short circuit within Replace the defective fuse. occur on further
the harness? ignition cycles?

No
Yes

Defective harness.
Complete
Replace harness.

471
Troubleshooting

Disconnect connector C10 from

MPDM.

Refer to the connector

investigation subtree.

No
Is there any problem with
the connector integrity?

With a multimeter, measure the voltage between the

Yes
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
Location, and Service Chart” in the Service
Manual MPDM C10 MPDM C10
Connector Connector
Pin 8 Pin 3

Turn ignition OFF. Yes

Is the measured voltage Defective MPDM.
Disconnect connector C12 from
over 11 V ? Replace the MDPM.
MPDM. No

Refer to the connector

investigation subtree.

Continued on next page

472
Troubleshooting

Continued from previous page

No
Is there any problem with
the connector integrity?

With a multimeter, check for continuity between the

Yes following points:
MPDM C10 MPDM C12
Defective connector. Connector Connector
Replace the connector as described in the Pin 1 Pin A
“Wire Harness Connector Identification,
Location, and Service Chart” in the Service MPDM C10 12V fuse box C14
Manual Connector Terminal

Pin 8 A1

MPDM C10 Ground C10

Connector Connector
Pin 3 Pin 4

Pin 4 Pin 4

Pin 9 Pin 4

Pin 10 Pin 4

- Continuity : Resistance is less than or equal to 2ohms.

Defective harness. Is there any evidence of a

Replace harness. continuity loss?
Yes

Defective MPDM.
Replace MPDM.

473
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. 3) Replace MPDM fuse.

4) MPDM internal failure. 4) Replace MPDM.

This error indicates that the MPDM has detected that

one of its relays is defective. The MPDM provides 16 Troubleshooting for errors F0080 to F0087 is similar
fused 12V outputs, eight of which are relay- and a single generic troubleshooting tree is provided.
controlled. Each relay has a corresponding error The specific fuse, relay, connector, and pin details
code. The relays are numbered K1 through K8. The for each error code are provided in the table below.
consequences of the error will depend on which The technician should use the table to look up the
relay is defective. information corresponding to the specific error code
and then use this information in the generic
The MPDM also monitors its internal fuses and will troubleshooting tree.
raise the corresponding error F0064 through F0079
if it detects a failure. There may be some cross-
sensitivity between fuse and relay error detection.

MPDM Table

474
Troubleshooting

Connector C12 (gray)

Connector C3

Connector C22

Connector C10

Connector C23

Connector C11 (black)

475
Troubleshooting

Connector C44

Connector C54

Connector C45

Connector C661

Connector C53

476
Troubleshooting

HMI displays or logs

Fault code F0080 to F0087

Are multiple
Yes No
powertrain fuse or relay
error messages displayed
Does the HMI also display
F0095 ? A
on the HMI?

No
Yes

Refer to the MPDM Table to

Refer to error F0095
determine which fuse and relay
troubleshooting tree.
to check.

With a multimeter perform a

Turn ignition OFF. continuity check on the fuse
related to the error message.

Replace relay in the MPDM and No Is the fuse blown or Yes Refer to error F0064 to
restart the truck. intermittent? F0079 troubleshooting tree.

Does the error still No

occur on further Complete
ignition cycles?

Yes

Defective MPDM.
Replace MPDM.

477
Troubleshooting

Disconnect connector C10 from

MPDM.

Refer to the connector

investigation subtree.

No
Is there any problem with
the connector integrity?

With a multimeter, measure the voltage between the

following points:
Yes
MPDM C10 MPDM C10
Defective connector. Connector Connector
Replace the connector as described in
the “Wire Harness Connector Pin 1 Pin 3
Identification, Location, and Service
MPDM C10 MPDM C10
Chart” in the Service Manual
Connector Connector
Pin 8 Pin 3

Turn ignition OFF. Yes

Is the measured voltage Defective MPDM.
Disconnect connector C12 from
over 11 V ? Replace the MDPM.
MPDM. No

Refer to the connector

investigation subtree.

Continued on next page

478
Troubleshooting

Continued from previous page

Is there any problem with No

the connector integrity?

With a multimeter, check for continuity between the

Pin 8 A1

MPDM C10 Ground C100

Connector Connector
Pin 3 Pin 4

Pin 4 Pin 4

Pin 9 Pin 4

Pin 10 Pin 4

- Continuity : Resistance is less than or equal to 2ohms.

Defective harness. Is there any evidence of a

Replace harness. continuity loss?
Yes

Defective MPDM.
Replace MPDM.

479
Troubleshooting

Power Steering System

The power steering system is an electro-hydraulic EHPS SME Motor
system which produces supplemental steering force
to assist the driver in steering the vehicle. The motor powers the hydraulic pump used by the
power steering system. It is powered by three-phase
Component descriptions AC voltage supplied by the inverter.

EHPS SME Inverter Hydraulic Circuit

The inverter controls the power steering motor. It The hydraulic circuit consists of a pump, reservoir,
consists of a power stage and a control stage. 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.
power the motor. The control stage is powered by
24V DC voltage. It is connected to the CAN network
and receives data from the motor through an LV
feedback loop.

480
Troubleshooting

F0010, F0011, F0012, F0013, or F0014 - Power Steering system fault

Error Description Possible Causes Possible Solutions

The EHPS motor controller detects 1) Causes covered in TM4 power 1) Troubleshoot specific error.
a problem resulting in loss of or steering troubleshooting guide.
reduced performance of the power
steering system. 2) EHPS system fluid too low 2) Check and add fluid

3) Leak or blockage in hydraulic 3) Resolve leak or blockage in

circuit. hydraulic circuit.

4) Cooling, ESS, air brake 4) Troubleshoot the specific

compressor, DCDC, or LV system error.
distribution fault.

5) CAN communication problem. 5) Resolve the CAN

communication problem.

This error indicates that the VCU has received a fault 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.
3403, 3603, 3605, 3608, 3609, 3607, 3701, 3702, • “Encoder harness connector” corresponds
3705, 3706, 3708, 3801, 3803, 3901, 3902, 3903, to connector C35 on the PACCAR vehicle.
4011, 4101, 4201, 4202, 4203, 4303, 5101, 5203, • “Temperature sensor connector”
5302, 5501, 5701, 5601 corresponds to connector C36 on the
PACCAR vehicle.
• “Main contactor connector” corresponds to
connector C38 on the PACCAR vehicle.

HMI displays or logs

Fault code F0010/F0011/F0012/F0013/F0014 and
EHPS service code XXXX
(any EHPS service codes listed in this section)

Refer to the specific service code in the

Dana TM4
EHPS Motor Controller MI06
Troubleshooting Guide

481
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

Turn ignition OFF and ON.

Is the error still No

occurring on further Complete
key ON cycles?

Yes

Defective EHPS motor controller.

Replace EHPS motor controller.

482
Troubleshooting

F0010, F0011, F0012, F0013, or F0014 EHPS service code 2403, 2404, 2405, 2406

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. troubleshooting guide.
not operable.

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.

*Note: The TM4 troubleshooting

guide only references 2402,
Turn ignition OFF.
2403, 2404, 2405.

Refer to relay investigation

subtree.
Investigate relay K008.

Is there any evidence

Defective relay.
of a defect between the
Replace relay.
Yes pins of the relay?

If the relay is not responsible for the failure and the root
cause couldn’t be found in the TM4 troubleshooting
guide, the EHPS Motor Controller should be replaced.

483
Troubleshooting

F0010, F0011, F0012, F0013, or F0014 EHPS service code 3602

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. troubleshooting guide.
not operable.

HMI displays or logs

Fault code F0010/F0011/F0012/F0013/F0014
and EHPS service code 3602

Refer to the Dana TM4

EHPS Motor Controller MI06 When troubleshooting EHPS service code
Troubleshooting Guide for code 3602. 3602, the technician is instructed to check
the hydraulic system for root causes.

Inspect the power steering oil

circuit for leaks and clogs.

Are there any leaks or

Repair the circuit
clogs in the power
accordingly.
Yes steering oil circuit?

Inspect the pump for possible

defects.

Continued on next page

484
Troubleshooting

Continued from previous page

Does the hydraulic pump

Replace EHPS pump and
connection to the EHPS motor
motor assembly.
Yes seem faulty?

Replace EHPS pump and Does the pump seem

motor assembly. unable to turn properly?
Yes

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.
Replace EHPS motor controller.

485
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. troubleshooting guide.
not operable.

486
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.

Does the HMI also

Refer to the corresponding error
display F0095 or
troubleshooting tree.
Yes F0008 ?

Have error code F0059,

Yes
Contact Dana for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power

Steering to 24V fuse box C20 and the
wire connecting the Power Steering to
the batteries.

Yes Is there any visible

Defective wiring.
signs of degradation on
Replace wiring.
the wires ?

Continued on next page No

487
Troubleshooting

Continued from previous page No

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 Yes connector
Service Chart” in the Service Manual integrity?

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Yes Can you find any traces of
instructions on the maintenance
burnt or corrosion on the
manual. If the defect can’t be solved
connection points ?
then replace the concerned system.

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.
Replace EHPS motor controller.

488
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. troubleshooting guide.
not operable.

489
Troubleshooting

HMI displays or logs

Fault code F0010/F0011/F0012/F0013/F0014
and EHPS service code 3610

Refer to the Dana TM4

EHPS Motor Controller MI06 When troubleshooting EHPS service code
Troubleshooting Guide for code 3610 3610, the technician is instructed to check the
LV distribution network for root causes.

Does the HMI also

Refer to the corresponding error
display F0095 or
troubleshooting tree.
Yes F0008 ?

Have error code F0059,

Yes
Contact Dana for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power

Steering to 24V fuse box C20 and the
wire connecting the Power Steering to
the batteries.

Yes Is there any visible

Defective wiring.
signs of degradation on
Replace wiring.
the wires ?

No
Continued on next page

490
Troubleshooting

Continued from previous page No

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 Yes connector
Service Chart” in the Service Manual integrity?

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Yes Can you find any traces of
instructions on the maintenance
burnt or corrosion on the
manual. If the defect can’t be solved
connection points ?
then replace the concerned system.

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.
Replace EHPS motor controller.

491
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. troubleshooting guide.
not operable.

492
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.

Does the HMI also

Refer to the corresponding error
display F0095 or
troubleshooting tree.
Yes F0008 ?

Have error code F0059,

Yes
Contact Dana for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power

Steering to 24V fuse box C20 and the
wire connecting the Power Steering to
the batteries.

Yes Is there any visible

Defective wiring.
signs of degradation on
Replace wiring.
the wires ?

Continued on next page No

493
Troubleshooting

Continued from previous page No

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 Yes the connector integrity?
Service Chart” in the Service Manual

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Yes Can you find any traces of
instructions on the maintenance
burnt or corrosion on the
manual. If the defect can’t be solved
connection points ?
then replace the concerned system.

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.
Replace EHPS motor controller.

494
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. troubleshooting guide.
not operable.

495
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.

Does the HMI also

Refer to the corresponding error
display F0095 or
troubleshooting tree.
Yes F0008 ?

Have error code F0059,

Yes
Contact Dana for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power

Steering to 24V fuse box C20 and the
wire connecting the Power Steering to
the batteries.

Yes Is there any visible

Defective wiring.
signs of degradation on
Replace wiring.
the wires?

Continued on next page No

496
Troubleshooting

Continued from previous page No

Disconnect connector C34 from EHPS

motor controller.

Refer to the connector investigation

subtree.

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Inspect the power steering oil

circuit for leaks and clogs.

Are there any leaks or

Repair the circuit
clogs in the power
accordingly.
Yes steering oil circuit?

Inspect the pump for possible

defects.

Continued on next page

500
Troubleshooting

Continued from previous page

Does the hydraulic pump

Replace EHPS pump and
connection to the EHPS
motor assembly.
Yes motor seem faulty?

Replace EHPS pump and Does the pump seem

motor assembly. unable to turn properly?
Yes

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. Yes simultaneously?

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.
Replace EHPS motor controller.

501
Troubleshooting

F0010, F0011, F0012, F0013, or F0014 EHPS service code 5201

Error Description Possible Causes Possible Solutions

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.

Inspect the power steering oil

circuit for leaks and clogs.

Are there any leaks or

Repair the circuit
clogs in the power
accordingly.
Yes steering oil circuit?

Inspect the pump for possible

defects.

Continued on next page

502
Troubleshooting

Continued from previous page

Does the hydraulic pump

Replace EHPS pump and
connection to the EHPS motor
motor assembly.
Yes seem faulty?

Replace EHPS pump and Does the pump seem

motor assembly. unable to turn properly?
Yes

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.
Replace EHPS motor controller.

503
Troubleshooting

F0010, F0011, F0012, F0013, or F0014 EHPS service code 5202

Error Description Possible Causes Possible Solutions

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. the hydraulic system for root causes.

Inspect the power steering oil

circuit for leaks and clogs.

Are there any leaks or

Repair the circuit
clogs in the power
accordingly.
Yes steering oil circuit?

Inspect the pump for possible

defects.

Continued on next page

504
Troubleshooting

Continued from previous page

Does the hydraulic pump

Replace EHPS pump and
connection to the EHPS motor
motor assembly.
Yes seem faulty?

Replace EHPS pump and Does the pump seem

motor assembly. unable to turn properly?
Yes

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.
Replace EHPS motor controller.

505
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.
failure of the power steering
system.

506
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. LV distribution network for root causes.

Yes Does the HMI also

Refer to the corresponding error
display F0095 or
troubleshooting tree.
F0008?

Have error code F0059,

Yes
Contact Dana for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power Steering

to 24V fuse box C20 and the wire connecting the
Power Steering to the batteries.

Yes Is there any visible

Defective wiring.
signs of degradation on
Replace wiring.
the wires ?

Continued on next page No

507
Troubleshooting

Continued from previous page No

Disconnect connector C34 from EHPS

motor controller.

Refer to the connector investigation

subtree.

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Yes Can you find any traces of
instructions on the maintenance
burnt or corrosion on the
manual. If the defect can’t be solved
connection points ?
then replace the concerned system.

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.
Replace EHPS motor controller.

508
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. troubleshooting guide.
not operable.

509
Troubleshooting

HMI displays or logs

Fault code F0010/F0011/F0012/F0013/F0014
and EHPS service code 5402

Refer to the Dana TM4

EHPS Motor Controller MI06 When troubleshooting EHPS service code
Troubleshooting Guide for code 5402. 5402 the technician is instructed to check
the main contactor.

Turn ignition OFF.

Refer to relay investigation

subtree.
Investigate relay K008.

Is there any evidence

Defective relay.
of a defect between the
Replace relay.
Yes pins of the relay?

Does the HMI also

Refer to F0095 troubleshooting tree.
display F0095?
Yes

Have error code F0059,

Yes
Contact DANA for F0060, F0020, F0000, or
further investigation. F0008 been raised
simultaneously?

Inspect the wire connecting the Power Steering

to 24V fuse box C20 and the wire connecting
the Power Steering to the batteries.

Continued on next page

510
Troubleshooting

Continued from previous page

Yes 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.

Inspect all connection points

between the EHPS motor controller
and the batteries.

Clean connectors according to the

Yes Can you find any traces of
instructions on the maintenance
burnt or corrosion on the
manual. If the defect can’t be solved
connection points?
then replace the concerned system.

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.
Replace EHPS motor controller.

511
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.
failure.

HMI displays or logs

Fault code F0132

Does the HMI also Yes Refer to the corresponding error

display F0011, F0012 or F0013,
troubleshooting tree.
F0014, F0008, F0095?

Defective EHPS motor controller.

Replace EHPS motor controller.

512
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.
time interval.
3) Loss of continuity caused by 3) Replace LV connector or
defective LV connector or harness per Service Manual.
harness.
4) Replace relay K015.
4) Defective relay K015.
5) Resolve CAN communication
5) CAN communication problem. problem.

6) EHPS motor controller internal 6) Replace EHPS motor

failure. controller.

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.

Connector C91

Connector C34

Connector C38

Connector C101

513
Troubleshooting

Connector C676

Circuit73

Connector C651.B

514
Troubleshooting

HMI displays
“Power steering No contact”

Refer to CAN investigation subtree

Investigate CAN D network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No Yes

Inspect fuse F13 on 24V fuse box

C20 and F10 on 12V fuse box C14.

Yes Is fuse F13 on Is fuse F10 on Yes

No
A 24V fuse box C20
blown or
12V fuse box C14
blown or B
intermittent? intermittent?

Disconnect connector C34 from

EHPS motor controller.

Refer to the connector

investigation subtree.

With a multimeter, measure the voltage between the

following points:
Defective connector.
Is there any
Yes Replace the connector as described
EHPS motor controller EHPS motor controller problem with the
in the “Wire Harness Connector
C34 Connector C34 Connector connector
No Identification, Location, and Service
integrity?
Pin 2 Pin 1 Chart” in the Service Manual

Continued on next page

515
Troubleshooting

Continued from previous page

Yes
Is the voltage over Defective EHPS motor controller.
24V? Replace EHPS motor controller.

Defective connector.
No Replace the connector as
Is there any problem with Yes described in the “Wire Harness
the connector integrity? Connector Identification,
Turn ignition OFF. Location, and Service Chart” in
the Service Manual
No

With a multimeter, check for continuity between the

Disconnect connector C38 from K015. following points:
Disconnect connector C91 from cradle. 24V fuse box C20 Relay K015 C38
Disconnect connector C651.B from VCU. Terminal Connector
Disconnect connector C101 from ground.
Remove fuse F13 and F10 in order to C3 Pin 1
take continuity measures from inside the
Relay K015 C38 EHPS motor controller
fuse box.
Connector C34 Connector

Pin 4 Pin 2
Ground C101 EHPS motor controller
Refer to the connector
Connector C34 Connector
investigation subtree.
Pin 3 Pin 1

12V fuse box C14 Relay K015 C38

Terminal Connector
A10 Pin 5

Cradle C91S Relay K015 C38

Connector Connector
Pin 16 Pin 2

Cradle C676P VCU C651.B

Connector Connector
Pin 16 Pin 44

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

516
Troubleshooting

Continued from previous page

Yes
Is there any proof of a Defective harness.
continuity loss? Replace harness.

Refer to relay investigation

subtree.
Investigate relay K015.

Is there any evidence Yes

Defective relay.
of a defect between the
Replace relay.
pins of the relay?

Contact Dana for further

investigation.

517
Troubleshooting

A
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.

Yes

Disconnect connector C34 from

Turn ignition OFF and
Refer to the connector EHPS motor controller.
disconnect F13 from 24V fuse
investigation subtree. Disconnect connector C651.B from
box C20.
VCU.

With a multimeter, check for short circuit between

the following points:

24V fuse box C20

Ground
Terminal
C3 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

518
Troubleshooting

Continued from previous page

Is there any evidence Yes Defective harness.

of a short circuit within the
Replace harness.
harness?

Refer to relay investigation

subtree.
Investigate relay K015.

Is there any evidence of a Yes

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 No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

519
Troubleshooting

B 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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C34 from
disconnect F10 from 12V fuse
investigation subtree. EHPS motor controller.
box C14.

With a multimeter, check for short circuit between

the following points:

12V fuse box C14

Ground
Terminal
A10 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

520
Troubleshooting

Continued from previous page

Is there any evidence Yes Defective harness.

of a short circuit within the
Replace harness.
harness?

Refer to relay investigation

subtree.
Investigate relay K015.

Is there any evidence of a Yes

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 No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

521
Troubleshooting

HVAC System
The Heating, Ventilation and Air Conditioning Condenser Fans
(HVAC) system provides heating, cooling, and
ventilation to the driver cab. The two condenser fans circulate forced air through
the condenser to carry away the waste heat. The
Component descriptions same fans are also used by the cooling system to
circulate air through the radiator.
Air Conditioning System
Blower
The air conditioning system consists of a standard
refrigeration circuit which uses a compressor, The blower circulates air through both the evaporator
condenser, expansion valve, and evaporator to and the heating system heat exchanger and into the
remove excess heat from the cab and reject it to the cab. 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.

The only parts of the air conditioning system which Heating System
are supplied by Dana are the A/C compressor and
the condenser fans. The remaining components are The heating system uses a hot water circuit to
outside the scope of this troubleshooting guide and deliver heat to the cab. The heating circuit consists
are presented here only to aid in understanding how of a reservoir, pump, heater, and a forced-air heat
the system operates. exchanger which delivers hot air to the cab. The
working fluid is a 50/50 water and ethylene glycol
Condenser and Evaporator mix.

The evaporator and condenser are forced-air heat The heat exchanger is not supplied by Dana and is
exchangers. The evaporator transfers heat from the outside the scope of this troubleshooting guide.
cab to the refrigerant, thereby cooling the cab. In the
process, the refrigerant undergoes a phase change Cabin heater
from liquid to vapor. Conversely, the condenser
transfers heat from the refrigerant to the surrounding The heater uses electric heating elements to heat
atmosphere as the refrigerant undergoes a phase the water in the heating circuit. It is powered by high
change from vapor to liquid. These components are voltage and communicates through the CAN/LIN.
not supplied by Dana and are outside the scope of
this troubleshooting guide. Heater Pump

Expansion Valve The heater pump circulates the hot water through
the heating circuit. It is powered by 12V low voltage
The expansion valve is between the condenser and and is controlled by the VCU through a hardwired LV
evaporator. It cools the refrigerant by causing it to connection.
undergo a sudden decrease in pressure. It is not
supplied by Dana and is outside the scope of this CAN/LIN
troubleshooting guide.
The CAN/LIN enables the heater, which uses a
A/C Compressor Local Interconnect Network (LIN) interface, to
communicate with the CAN network. It is powered by
The A/C compressor is between the evaporator and 12V low voltage.
condenser. Its function is to compress and superheat
the refrigerant, which is in vapor phase, before it
enters the condenser. It is a variable-speed, screw-
type compressor. It is powered by high voltage and
communicates via the CAN network.

522
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.
as this could trigger other errors.

HMI displays or logs

Fault code F0053 and
Cabin heating system fault 1/2/4/5/8

Does the HMI also Yes Refer to error F0133

display error troubleshooting tree.
F0133?

Defective heater.
Replace heater.

523
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.
2 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. F0158 may appear, the
technician should troubleshoot error F0158. HV
heater wiring may also be a problem source.

524
Troubleshooting

HMI displays or logs Fault code F0053

and Cabin heating system fault 3

Wait 1 hour for the truck to

cooldown.

Turn the vehicle ignition ON and

try to activate the heater to
confirm operation.

Does the HMI still

No
Yes display “F0053 -
Is the heater Complete
Cabin heating
operating?
system fault
Fault reason 3.”?

No
Yes

Contact Dana for

further investigation.

Does the HMI Yes Refer to error F0158

also display troubleshooting tree.
error F0158?

No
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 Yes
Voltage Shutdown Procedures DANA before restarting the
blown or
defined in the Service Manual truck.
intermittent?
and Diagnostic Guide.

No
No

Observing proper safety Defective heater.

precautions, open the HV Replace heater.
junction box.

525
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. heating circuit.

3) Cabin heater internal failure. 3) Replace cabin heater.

HMI displays or logs

Fault code F0053 and
Cabin heating system fault 6/7

Refer to error F0133

troubleshooting tree.

526
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. harness per Service Manual.

4) Blown HV fuse F5. 4) Replace HV fuse F5.

5) Defective HV harness or 5) Replace HV harness.

connector.
6) Replace cabin heater.
6) Cabin heater internal failure.

This error indicates that the VCU has received a

warning message from the heater indicating that
the heater may experience reduced performance.

Connector C721

Connector C73

Connector C709

527
Troubleshooting

HMI displays or logs

Fault code F0054

Does the HMI also Yes Refer to error F0026

display error troubleshooting tree.
F0026?

Place the vehicle in accessory

mode.

No
Is error F0054 Troubleshoot the high voltage.
still raised? Add the correct section here.

Yes

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.

Continued on next page

528
Troubleshooting

Continued from previous page

Is fuse F13 blown or

intermittent?
Yes
A
No

Disconnect connector C73 from

heater.
Remove fuse F13 in order to
take continuity measures from
inside the fuse box.

Refer to connector
investigation subtree.

With a multimeter, check for continuity between the

following points:
C73 Heater 12V fuse box C14
Connector pin Terminal

Pin 1 C3

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

529
Troubleshooting

Continued from previous page

Is there any evidence of Yes 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
defined in the Service Manual Refer to connector
and Diagnostic Guide. investigation subtree.

No Is there any problem with

the connector integrity?
With a multimeter, check for continuity between the
following points:
Heater C721P HV Jct Box C709P Yes
Connector pin Connector pin

Pin 1 Pin 2 Defective connector.

Replace harness.
Heater C721P HV Jct Box C709P
Connector pin Connector pin
Pin 2 Pin 1

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

530
Troubleshooting

Continued from previous page

Is there any evidence of Yes 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.

No Defective heater.
Is fuse F5 blown?
Replace heater.

Yes

With a multimeter, check for short circuit between

the following points:
Heater C721P
Ground
Connector pin

Pin 1 Ground

-HV short: Resistance measurement is less than

350k-ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

531
Troubleshooting

Continued from previous page

Is there any evidence Yes 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 Yes Defective heater.

again? Replace heater.

Complete

532
Troubleshooting

A
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 No

Complete
during a test drive?

Yes
Turn ignition OFF and
disconnect F13 from 12V fuse
box C14.

Disconnect connector C73 from

heater.

Refer to connector
investigation subtree.

No
Continued on next page

533
Troubleshooting

No 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.

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Defective heater.
Replace heater.

534
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.

failure.

HMI displays or logs

Fault code F0055

Refer to the heating circuit

investigation subtree.

Was any root cause found Yes

Complete
in the heating circuit?

Defective heater pump.

Replace heater pump.

535
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.
network.
3) Replace 24V fuse F4.
3) Blown 24V fuse F4.
4) Replace 24V fuse F5.
4) Blown 24V fuse F5.
5) Replace 24V fuse F14.
5) Blown 24V fuse F14.
6) Replace 24V fuse F15.
6) Blown 24V fuse F15.
7) Replace LV connector or
7) Loss of continuity due to harness per Service Manual.
defective LV connector or
harness. 8) Replace condenser fan 1 or 2.

8) Condenser fan 1 or 2 internal

failure.

Connector C82 Connector C89

536
Troubleshooting

HMI displays or logs

Fault code F0105

Does the HMI also

display F0008, F0095, Yes Refer to the corresponding error
or condenser fan no troubleshooting tree.
contact?

Visually inspect condenser fan 1

and 2.

Is either fan damaged, Yes

obstructed, or otherwise Clear obstruction or replace fan.
unable to turn freely?

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Inspect fuse F4 in the 24V fuse

box C20.

Continued on next page

537
Troubleshooting

Continued from previous page

A
Is fuse F4 blown or Yes
intermittent?

Inspect fuse F14 in the 24V fuse

box C20.

B
Is fuse F14 blown or Yes
intermittent?

Disconnect connector C82 from

condenser fan 2.
Remove fuse F4 and F14 in order
to take continuity measures
from inside the fuse box.

Refer to the connector

investigation subtree.

Continued on next page

538
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
Condenser fan 2 C82 24V fuse box C20
Connector pin Terminal

Pin 1 A4

Condenser fan 2 C82 24V fuse box C20

Connector pin Terminal
Pin 6 C4

Condenser fan 2 C82

Ground
Connector pin

Pin 8 Ground
Condenser fan 2 C82 Condenser fan 2 C82
Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Inspect fuse F5 in the 24V fuse

box C20.

Continued on next page

539
Troubleshooting

Continued from previous page

C
Yes
Is fuse F5 blown or
intermittent?

Inspect fuse F15 in the 24V fuse

box C20.

Is fuse F15 blown or

intermittent?
Yes
D
No

Disconnect connector C89 from

condenser fan 1.
Remove fuse F5 and F15 in order
to take continuity measures
from inside the fuse box.

Refer to the connector

investigation subtree.

No
Continued on next page

540
Troubleshooting

No 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 A5

Condenser fan 1 C89 24V fuse box C20

Connector pin Terminal
Pin 6 C5

Condenser fan 1 C89

Ground
Connector pin

Pin 8 Ground

Condenser fan 1 C89 Condenser fan 1 C89

Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Replace condenser fan 1.

Yes
Is the error resolved? Complete

Replace condenser fan 2.

541
Troubleshooting

Complete

A No

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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C82 from
disconnect F4 from 24V fuse box
investigation subtree. condenser fan 2.
C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 2 C82
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.

Continued on next page

542
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Defective condenser fan 2.

Replace condenser fan 2.

543
Troubleshooting

Complete

B No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C82 from
disconnect F14 from 24V fuse
investigation subtree. condenser fan 2.
box C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 2 C82
Ground
Connector pin

Pin 6 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

544
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 2.

Replace condenser fan 2.

545
Troubleshooting

Complete

C No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C89 from
disconnect F5 from 24V fuse box
investigation subtree. condenser fan 1.
C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 1 C89
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.

Continued on next page

546
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 1.

Replace condenser fan 1.

547
Troubleshooting

Complete

D No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C89 from
disconnect F15 from 24V fuse
investigation subtree. condenser fan 1.
box C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 1 C89
Ground
Connector pin

Pin 6 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

548
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 1.

Replace condenser fan 1.

549
Troubleshooting

F0111 - Limited/No defrost functionality

Error Description Possible Causes Possible Solutions

The VCU has detected a fault 1) Cabin heater, heater pump, or 1) Troubleshoot specific error.
which could result in reduced A/C compressor fault, or low
performance of the defrost refrigerant pressure in A/C
function. system.

This error indicates that the VCU has detected one An error code F0053, F0055, F0134, F0135, F0136,
or more of the following specific HVAC faults: F0141, or F0158 corresponding to the specific fault
should also appear. The technician should
1) Heater fault troubleshoot the specific code.
2) Heater pump fault
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

Fault code F0111

Does the HMI also display Yes Refer to the corresponding error
F0053, F0055, F0134, F0135,
troubleshooting tree.
F0136, F0141, or F0158?

Contact DANA for further

investigation.

550
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. heating circuit.

3) Cabin heater internal failure. 3) Replace cabin heater.

HMI displays or logs

Fault code F0133

Does the HMI also Yes Refer to the corresponding error

display F0055, F0134,
troubleshooting tree.
or F0136?

Turn the heater OFF and wait for

Turn the heater ON.
it to cool down.

No Complete. If error occurs again

Does the error occur again?
later, continue with next steps.

Yes

Refer to the heating circuit

Investigation subtree.

Was any root cause found Yes

Complete
in the heating circuit?

Defective heater.
Replace heater.

551
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.

HMI displays or logs

Fault code F0134

Refer to the heating circuit

Investigation subtree.

Was any root cause found Yes

Complete
in the heating circuit?

Defective heater pump.

Replace heater pump.

552
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. heating circuit.

3) Heater pump internal failure. 3) Replace heater pump.

4) Cabin heater internal failure. 4) Replace cabin heater.

HMI displays or logs

Fault code F0135

Does the HMI also Yes Refer to error F0133

display error F0133? troubleshooting tree.

Refer to the heating circuit

investigation subtree.

Was any root cause found Yes

Complete
in the heating circuit?

Replace heater pump.

Yes
Is the error resolved? Complete

Replace heater.

553
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 harness per Service Manual.
harness.
4) Flush and refill heating circuit
4) Wrong fluid used in heating with correct fluid.
circuit.
5) Resolve air lock in heating
5) Air lock in heating circuit. circuit.

6) Heater pump internal failure. 6) Replace heater pump.

Connector C74

Circuit73

Connector C651.B

554
Troubleshooting

HMI displays or logs

Fault code F0136

Does the HMI also Yes 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 No Drain and flush heating circuit.

heating circuit the
Refill with correct fluid.
correct specification?

Yes

Use the service interface to

activate the heater pump.

No Does fluid flow out of Yes Does the heater pump run
the reservoir when the
when requested?
pump is running?

Yes No

Disconnect hose from pump

outlet. Pinch off hose. A
Continued on next page

555
Troubleshooting

Continued from previous page

Is the pump outlet Yes 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 No Check for obstructions between

the outlet when the
the reservoir and pump.
pump is running?

No
Yes Is the heating circuit
obstructed? A
Yes

Reconnect the hose to the pump Clear obstruction, reconnect

outlet. Refill fluid as needed. hoses, and refill fluid as needed.

Continued on next page

556
Troubleshooting

Continued from previous page

Is the problem Yes

Complete
resolved?

Disconnect the heating circuit

one section at a time and check
for obstructions.

Is the heating circuit Yes Clear obstruction, reconnect

obstructed? hoses, and refill fluid as needed.

Defective heater pump.

Replace heater pump.

557
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.

B
Is fuse F15 blown or Yes
intermittent?

Disconnect connector C74 from

heater pump.
Disconnect connector C651.B
from VCU.
Remove fuse F15 in order to
take continuity measures from
inside the fuse box.

Refer to the connector

investigation subtree.

Continued on next page

558
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
C74 12V fuse box C14
Connector pin C5

Pin 3 C5

C74 VCU C651.B

Connector pin Connector pin

Pin 2 Pin 63

Pin 4 Pin 57

C74
Ground
Connector pin

Pin 1 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Defective heater pump.

Replace heater pump.

559
Troubleshooting

Complete

B No

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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C74 from
disconnect F15 from 12V fuse
investigation subtree. heater pump.
box C14.

With a multimeter, check for short circuit between

the following points:
C74
Ground
Connector pin

Pin 3 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

560
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Defective heater pump.

Replace heater pump.

561
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.
3) Pressure sensor failure.
3) Replace pressure sensor.
4) Defective wiring to pressure
sensor. 4) Replace LV connector or
harness per Service Manual.

This error indicates that the VCU has detected

that the refrigerant pressure in the air conditioner
is lower than expected. The refrigerant pressure is
measured by a dedicated pressure sensor wired
directly to the VCU.

Connector SS681
Connector C7

Circuit73

Connector C651.B

562
Troubleshooting

HMI displays or logs

Fault code F0141

Does the HMI also

display A/C compressor Yes 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 Yes Inspect refrigerant lines for any

pressure lower than
evidence of a leak.
expected?

Is there any evidence Yes Repair and recharge the A/C

Turn ignition OFF.
of a leak? system as needed.

No
Locate the A/C pressure sensor.

Recharge the A/C system as

needed.

Disconnect connector C7 from

pressure sensor.
Disconnect connector C651.B
from VCU.
Disconnect connector SS681.

Continued on next page

563
Troubleshooting

Continued from previous page

Defective connector.
Yes
Refer to the connector Is there any problem with Replace the connector as described in the “Wire
investigation subtree. the connector integrity? Harness Connector Identification, Location, and
Service Chart” in the Service Manual

With a multimeter, check for continuity between the

following points:
Pressure sensor C7 VCU C651.B
Connector pin Connector pin

Pin 1 Pin 12

Pressure sensor C7 SS681S

Connector pin Connector pin

Pin 2 Pin E

- Continuity : Resistance is less than or equal to

2ohms.

No
Defective harness. Yes Is there any evidence of
Replace the pressure sensor.
Replace harness. continuity loss?

No Is error F0141 still

Complete
raised?

Yes

Contact DANA for further

investigation.

564
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.
harness.
3) Replace A/C compressor.
3) A/C compressor internal
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 A/C compressor
monitors continuity between the HVIL pins on its HV
connector (C729). If this connector is unplugged
unsafely, the HVIL will be broken and the DCDC will
send an error message via CAN.

If error F0061, F0062, or F0063 also appears, it is

possible that connector C710 on the HV junction box
is disconnected or faulty.

3
4
Connector C710

3
4
Connector C729

565
Troubleshooting

HMI displays or logs

Fault code F0142

A
Does the HMI also Yes
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.

Continued on next page

566
Troubleshooting

Continued from previous page

Is connector C729 Yes

Plug it in and restart the vehicle.
unplugged?

Disconnect connector C729 from Refer to the connector

A/C compressor. investigation subtree.

Defective connector. Yes Is there any problem with

Replace harness. the connector integrity?

With a multimeter, check for continuity between the

following points:
AC compressor C729P AC compressor C729P
Connector pin Connector pin

Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Defective harness. Yes Is there any evidence of

Replace harness. continuity loss?

Defective A/C compressor.

Replace A/C compressor.

567
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 Yes

Plug it in and restart the vehicle.
unplugged?

Disconnect connector C729 from

A/C compressor.
Disconnect connector C710 from
HV junction box.

Continued on next page

568
Troubleshooting

Continued from previous page

Refer to the connector

investigation subtree.

Is there any problem with Yes 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

HV Jct Box C710P HV Jct Box C710P

Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Defective A/C compressor.

Replace A/C compressor.

569
Troubleshooting

F0143 - Potential High Voltage Hazard! Heater HVIL Fault

Error Description Possible Causes 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.

570
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. 3) Replace HV fuse F6.

4) Defective HV connector or 4) Replace HV harness.

harness.
5) Replace A/C compressor.
5) A/C compressor internal
failure.

3
Connector C71 4
Connector C710

3
4
Connector C729

571
Troubleshooting

HMI displays or logs

Fault code F0158

Does the HMI Yes Refer to F0026 troubleshooting

also display error tree.
F0026?

Disconnect connector C71 from

A/C compressor.

Refer to the connector

investigation subtree.

With a multimeter, check the voltage between the

following points:
AC compressor C71 AC compressor C71
Connector pin Connector pin

Pin 3 Pin 6

Continued on next page

572
Troubleshooting

Continued from previous page

Is the voltage No 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.

Refer to the connector

investigation subtree.

No Is there any problem with

the connector integrity?
With a multimeter, check for continuity between the
following points:
AC compressor C729P HV Jct Box C710P Yes
Connector pin Connector pin

Pin 1 Pin 1 Defective connector.

Replace harness.
Pin 2 Pin 2

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

573
Troubleshooting

Continued from previous page

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Connect connector C710 to HV

junction box.

Observing proper safety

precautions, open the HV
junction box.

Inspect fuse F6 in the HV

Complete
junction box.

No Refer to the CAN Investigation

Is fuse F6 blown or
subtree. Is error F0158 still raised?
intermittent?
Investigate CAN A network.

Yes
Yes

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.

No
Does fuse F6 blow
again during a test Complete
drive?

Yes
Continued on next page
574
Troubleshooting

Continued from previous page

Yes

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.

Is there any evidence Yes Defective harness.

of a short circuit within
Replace harness.
the harness?

Defective A/C compressor.

Replace A/C compressor.

575
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. 2) Replace 24V fuse F5.
3) Blown 24V fuse F15.
3) Replace 24V fuse F15.
4) Loss of continuity caused by
defective LV harness or 4) Replace LV connector or
connector. harness per Service Manual.

5) Condenser fan 1 internal 5) Replace condenser fan 1.

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.

Connector C89

576
Troubleshooting

HMI displays
“No contact with condenser fan 1.”

A
Inspect fuse F5 in the 24V fuse Is fuse F5 blown or Yes
box C20. intermittent?

Inspect fuse F15 in the 24V fuse

box C20.

B
Is fuse F15 blown or Yes
intermittent?

Disconnect connector C89 from

condenser fan 1.
Remove fuse F5 and F15 in order
to take continuity measures
from inside the fuse box.

Refer to the connector

investigation subtree.

Defective connector.
Yes
Replace the connector as described in the “Wire Is there any problem with
Harness Connector Identification, Location, and the connector integrity?
Service Chart” in the Service Manual

No
Continued on next page

577
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 A5

Condenser fan 1 C89 24V fuse box C20

Connector pin Terminal
Pin 6 C5

Condenser fan 1 C89

Ground
Connector pin

Pin 8 Ground

Condenser fan 1 C89 Condenser fan 1 C89

Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN investigation

subtree.
Investigate CAN C network.

No
Is the error still raised? Complete

Yes

Defective condenser fan 1.

Replace condenser fan 1.

578
Troubleshooting

Complete

A No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C89 from
disconnect F5 from 24V fuse box
investigation subtree. condenser fan 1.
C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 1 C89
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.

Continued on next page

579
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 1.

Replace condenser fan 1.

580
Troubleshooting

Complete

B No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C89 from
disconnect F15 from 24V fuse
investigation subtree. condenser fan 1.
box C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 1 C89
Ground
Connector pin

Pin 6 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

581
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 1.

Replace condenser fan 1.

582
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. 2) Replace 24V fuse F4.
3) Blown 24V fuse F14.
3) Replace 24V fuse F14.
4) Loss of continuity caused by
defective LV harness or 4) Replace LV connector or
connector. harness per Service Manual.

5) Condenser fan 2 internal 5) Replace condenser fan 2.

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.

Connector C82

583
Troubleshooting

HMI displays
“No contact with condenser fan 2.”

A
Inspect fuse F4 in the 24V fuse Is fuse F4 blown or Yes
box C20. intermittent?

Inspect fuse F14 in the 24V fuse

box C20.

B
Is fuse F14 blown or Yes
intermittent?

Disconnect connector C82 from

condenser fan 2.
Remove fuse F4 and F14 in order
to take continuity measures
from inside the fuse box.

Continued on next page

584
Troubleshooting

Continued from previous page

Refer to the connector

investigation subtree.

With a multimeter, check for continuity between the

following points:
Condenser fan 2 C82 24V fuse box C20
Connector pin Terminal

Pin 1 A4

Condenser fan 2 C82 24V fuse box C20

Connector pin Terminal
Pin 6 C4

Condenser fan 2 C82

Ground
Connector pin

Pin 8 Ground

Condenser fan 2 C82 Condenser fan 2 C82

Connector pin Connector pin
Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

585
Troubleshooting

Continued from previous page

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN investigation

subtree.
Investigate CAN C network.

No
Is the error still raised? Complete

Yes

Defective condenser fan 2.

Replace condenser fan 2.

586
Troubleshooting

A 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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C82 from
disconnect F4 from 24V fuse box
investigation subtree. condenser fan 2.
C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 2 C82
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.

Continued on next page

587
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Defective condenser fan 2.

Replace condenser fan 2.

588
Troubleshooting

B 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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C82 from
disconnect F14 from 24V fuse
investigation subtree. condenser fan 2.
box C20.

With a multimeter, check for short circuit between

the following points:
Condenser fan 2 C82
Ground
Connector pin

Pin 6 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

589
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective condenser fan 2.

Replace condenser fan 2.

590
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.
3) Loss of continuity caused by
defective LV harness or 3) Replace LV connector or
connector. harness per Service Manual.

4) A/C compressor internal 4) Replace heater.

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.

Connector C71

591
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?
Yes
A
No

Disconnect connector C71 from

A/C compressor.
Remove fuse F12 in order to
take continuity measures from
inside the fuse box.

Refer to the connector

investigation subtree.

Continued on next page

592
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
AC compressor C71 12V fuse box C14
Connector pin Terminal

Pin 6 C2

AC compressor C71
Ground
Connector pin
Pin 3 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN Investigation

subtree.
Investigate CAN A network.

No
Is the error still raised? Complete

Yes

Defective A/C compressor.

Replace A/C compressor.
593
Troubleshooting

Complete

A No

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?

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C71 from
disconnect F12 from 12V fuse
investigation subtree. A/C compressor.
box C14.

With a multimeter, check for short circuit between

the following points:
AC compressor C71
Ground
Connector pin

Pin 6 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

594
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

again during a test Complete
drive?

Yes

Defective A/C compressor.

Replace A/C compressor.

595
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.
3) Loss of continuity caused by
defective LV harness or 3) Replace LV connector or
connector. harness per Service Manual.

4) Cabin heater internal failure. 4) Replace cabin heater.

5) CAN/LIN internal failure. 5) Replace CAN/LIN.

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.

Connector C72

Connector C73

596
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?
Yes
A
No

Disconnect connector C73 from

heater.
Disconnect connector C72 from
CAN/LIN.
Remove fuse F13 in order to
take continuity measures from
inside the fuse box.

Refer to the connector

investigation subtree.

Continued on next page

597
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
Heater C73 12V fuse box C14
Connector pin Terminal

Pin 1 C3

Heater C73
Ground
Connector pin
Pin 8 Ground

Heater C73 CAN/LIN C72

Connector pin Connector pin

Pin 6 Pin 4

CAN/LIN C72 12V fuse box C14

Connector pin Terminal
Pin 5 C3

CAN/LIN C72
Ground
Connector pin
Pin 6 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Continued on next page

598
Troubleshooting

Continued from previous page

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the CAN investigation

subtree.
Investigate CAN C network.

No
Is the error still raised? Complete

Yes

Contact Dana for further

investigation.

599
Troubleshooting

A
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 No

Complete
during a test drive?

Yes
Turn ignition OFF and
disconnect F13 from 12V fuse
box C14.

Disconnect connector C73 from

heater.
Disconnect connector C72 from
CAN/LIN.

Refer to the connector

investigation subtree.

No Continued on next page

600
Troubleshooting

No Continued from previous page

With a multimeter, check for short circuit between

the following points:
Heater C73
Ground
Connector pin

Pin 1 Ground

CAN/LIN C72
Ground
Connector pin

Pin 5 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Contact Dana for further

investigation.

601
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
VCU 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. It is
powered by 12V low voltage and is connected to The Supervisory controller is a secondary safety
other equipment either through the CAN network or controller which monitors safety-critical signals on
through dedicated LV connections. the vehicle and shuts down the high voltage system
of the vehicle if the VCU fails to take appropriate
HMI action. It is connected to four CAN networks, CAN A
– CAN D.
The Human-Machine Interface (HMI) is an
interactive display in the cab which allows the driver

602
Troubleshooting

F0050 - Turn on Hazard Lights!

Error Description Possible Causes Possible Solutions

Hazard lights requested due to 1) ESS or Supervisory controller 1) Troubleshoot specific error.
BMS limp mode or Supervisory fault.
controller safety shutdown.

This is a warning message for the driver indicating This message is expected to be accompanied by the
that the hazard lights should be turned on due to one specific error that triggered the warning, either
of the following situations: F0026 (BMS fault) or F0051/F0052 (Supervisory
controller shutdown). The technician should
• BMS limp mode (vehicle is drivable under troubleshoot F0026 or F0051/F0052.
very restricted conditions due to BMS fault).
• Supervisory controller requests shutdown. If error F0050 appears alone, the technician should
contact Dana for further investigation.

HMI displays or logs

Fault code F0050
“Turn on Hazard Lights!”

Does the HMI also No No

Is there a turtle lamp Contact Dana for further
display F0026, F0051
on the dashboard? investigation.
or F0052?

Yes Yes

Check HMI and/or fault log

Refer to the corresponding error
and troubleshoot any
troubleshooting tree.
recent faults.

603
Troubleshooting

F0051 - Powertrain safety system requested shutdown

F0052 - Powertrain safety system requested shutdown

Error Description Possible Causes Possible Solutions

Supervisory controller has 1) Mitigation of potentially 1) Contact Dana.

requested the vehicle to shut down hazardous situation by
due to a potentially hazardous Supervisory controller.
situation.

The Supervisory controller will take this action as a Given that this is an exceptional situation potentially
last line of defense if a shutdown is not requested by involving failure of other safety systems, all
another device (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’’
(Where “X” any reason number)

Contact Dana for further

investigation.

604
Troubleshooting

F0057 - High voltage system fault. Vehicle restart will be prohibited.

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.

605
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.

3) Loss of continuity on cut loop

signal wire (wire cut,
damaged, or 12V fuse F20
blown) AND loss of 12V to
ESS or loss of CAN
communication from ESS to
VCU.

The cut loop is a section of LV wiring which can

be cut by first responders to shut down the HV
system in an emergency.

If the cut loop is broken:

• Contactors inside the S-Box will open to

isolate the high voltage battery packs from
the HV distribution system.
• The VCU will notify the driver immediately
by raising error F0058 and will prohibit
restarting the vehicle. Connector C40

If error F0058 has been raised, a service reset is

required to clear the error and restart the vehicle.
Attempting to start the vehicle without clearing the
error will raise an additional error message F0108.

A break in the cut loop is also expected to trigger

various other errors including F0016, BMS no
contact, and F0005/F0006/F0007 (fault reason
13).

If a cut loop problem is indicated, the cut loop

should always be inspected before Connector C91
troubleshooting any other possible root cause.

If the cut loop is intact, the cause of the error may

be a blown fuse or a discontinuity elsewhere in the
wiring.

606
Troubleshooting

Connector C367P (pin) Connector C367S (socket)

Connector C676

Circuit73

Connector C651.B

607
Troubleshooting

HMI displays or logs

Fault code F0058

Has the cut loop been Yes Contact Dana for further
cut previously? investigation.

Turn ignition OFF.

No Yes
Is fuse F20 on 12V fuse box Does the HMI also display Refer to the specific error
C14 blown or intermittent? F0064, F0069, or F0071? troubleshooting tree.

No
Yes

A Disconnect connector C11 from MPDM.

Disconnect connector C93.
Disconnect connector C75.
Disconnect connector C76.
Disconnect connector C367.
Disconnect connector C40.
Disconnect connector C50.
Disconnect connector C651.B from VCU.

Refer to connector investigation

subtree.

Continued on next page No

608
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 C75
Connector pin Connector pin
Pin 7 Pin 1

Pin 8 Pin 4

C93S C76
Connector pin Connector pin
Pin 5 Pin 1

Pin 6 Pin 4

C93P C40S
Connector pin Connector pin
Pin 8 Pin 11

Pin 6 Pin 9

C40P C367S
Connector pin Connector pin
Pin 11 Pin 8

Pin 9 Pin 11

Pin 12 Pin 12
C44 S-Box C367P
Connector pin Connector pin
Pin 1 Pin 8

Pin 2 Pin 8

Pin 14 Pin 12

Pin 13 Pin 11
- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

609
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 C367P
Connector Connector
Pin 9 Pin 10

C40S 12V fuse box C14

Connector Terminal
Pin 27 C10

- Continuity : Resistance is less than or equal to 2ohms.

Is there any evidence of Yes Defective harness.

a continuity loss ? Replace harness.

No Continued on next page

610
Troubleshooting

Continued from previous page No

Refer to relay investigation

subtree.
Investigate relays K006 and K007.

Is there any evidence of a Yes

Defective relay.
defect between the pins of
Replace relay.
the relay?

Refer to CAN investigation subtree

Investigate CAN A network

Complete

Were you able to find a Yes Take the actions Is the error code still
problem in the CAN A
prescribed in the subtree. displayed?
network?

No Yes

Contact Dana for further

investigation.

611
Troubleshooting

Complete

A No

Remove and replace blown fuse Did fuse F20 blow again
Restart the vehicle.
F20 from 12V fuse box C14. during test drive?

Yes
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 Yes

investigation subtree. the connector integrity?

Defective connector.
Replace the connector as described in
With a multimeter, check for short circuit between
the “Wire Harness Connector
the following points:
No Identification, Location, and Service
12V fuse box C14 Chart” in the Service Manual
Ground
Terminal
C10 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

612
Troubleshooting

Continued from previous page

Is there any evidence of a Yes 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 No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

613
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). 2) Analog HVIL fault. 2) Troubleshoot specific error.

The purpose of the HVIL is to provide a warning if If an HVIL fault occurs while in driving mode, the
any HV connector is unplugged without the HV VCU will alert the driver immediately and then, after
distribution being safely ended. The vehicle uses two a delay of 1 hour, the VCU will request to open
different methods to detect unplugged connectors, contactors to shut down the vehicle and isolate the
software HVIL and analog HVIL (explained below). high voltage system. If the fault occurs in charging
Error F0061 will be triggered regardless of whether mode, the contactors will be opened immediately. In
the fault is detected by software HVIL or analog either case, the vehicle is prohibited from restarting
HVIL. until the error is cleared.

The software HVIL strategy is used by certain One or more of F0061, F0062, and F0063 may be
onboard equipment including the DCDC, A/C raised depending on the circumstances in which the
compressor, TMS, air brake compressor, and BMS. fault occurred:
These devices monitor their HV connectors locally
and alert the VCU via CAN if a connector is • F0061 HVIL fault prevents closing of
unplugged. If this is the case, a specific error contactors if fault occurs prior to closing of
message (F0026, F0139, F0140, F0142, F0143, contactors (only possible for analog HVIL).
F0144, or F0146) will be raised and the technician HVIL fault will open contactors immediately if
should troubleshoot the specific error. in charging mode or if fault is detected within
the first 5 seconds of entering driving mode.
In contrast, other onboard equipment is connected to Also, HVIL fault will open contactors in
the analog HVIL, which is a physical circuit that runs driving mode when the park brake is applied
through various HV connectors on the vehicle. If a continuously for 3 seconds.
connector is unplugged unsafely, the HVIL will be • F0062 is raised upon attempted startup of
broken and the VCU will detect the loss of signal the vehicle when an HVIL fault was detected
voltage on the circuit. Because the analog HVIL is a prior to startup, including on a previous key
single series circuit, the VCU will detect the cycle.
presence of a discontinuity but not its location. The • F0063 is raised immediately if an HVIL fault
technician should consult the analog HVIL occurs while in driving mode.
troubleshooting subtree.

614
Troubleshooting

HMI displays or logs

Fault code F0061 or F0062

Does the HMI also display Yes 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 Yes Repair as prescribed

the HVIL analog circuit? in the in subtree.

Contact Dana for further

investigation.

615
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.

The purpose of the HVIL is to provide a warning if If an HVIL fault occurs while in driving mode, the
any HV connector is unplugged without the HV VCU will alert the driver immediately and then, after
distribution being safely ended. The vehicle uses two a delay of 1 hour, the VCU will request to open
different methods to detect unplugged connectors, contactors to shut down the vehicle and isolate the
software HVIL and analog HVIL (explained below). high voltage system. If the fault occurs in charging
Error F0063 will be triggered regardless of whether mode, the contactors will be opened immediately. In
the fault is detected by software HVIL or analog either case, the vehicle is prohibited from restarting
HVIL. until the error is cleared.

616
Troubleshooting

HMI displays or logs

Fault code F0063

Apply parking brake and put

truck in ready mode.

Does the HMI also Yes 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.

617
Troubleshooting

F0092 - High Voltage system fault

Error Description Possible Causes Possible Solutions

BMS has requested a shutdown of 1) ESS fault. 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

Does the HMI also display Yes Refer to the corresponding

F0026? error troubleshooting tree.

Contact Dana for further

investigation.

618
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.
2) Replace LV distribution fuse
2) Blown LV distribution fuse F1. F1.

3) Blown LV distribution fuse F2. 3) Replace LV distribution fuse

F2.
4) Short circuit due to defective
LV connector or harness. 4) Replace LV connector or
harness per Service Manual.
5) Loss of continuity due to
damaged, corroded, or loose 5) Replace LV connector or
LV bolted connection. harness per Service Manual.

6) At least one low voltage 6) Replace low voltage battery or

battery defective, not to spec, repair battery wiring.
or wired incorrectly.
7) Replace equalizer.
7) Equalizer internal failure.

619
Troubleshooting

HMI displays or logs

Fault code F0095

Has error F0008 or F0144 Yes Refer to the specific error

been raised previous to this
troubleshooting tree.
error being raised?

Has a ‘CAN no contact with DCDC’ Yes Refer to the specific error
error been raised previous to this
troubleshooting tree.
error being raised?

A
Inspect fuse F1 and F2 in the Is fuse F1 blown or Yes
low voltage battery box. intermittent?

B
Is fuse F2 blown or Yes
intermittent?

No
Continued on next page

620
Troubleshooting

No 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 GND strip1

RT087 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Is there any proof of a

short-circuit to the ground Yes Defective wiring.
in the main low voltage Replace any defective wiring.
distribution circuit?

No
Continued on next page

621
Troubleshooting

No 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.

List
RT020
RT005
RT004
RT019
Is there any proof of a short- RT014
circuit to the hot wire in the Yes Defective wiring. RT025
main low voltage distribution Replace any defective wiring. RT023
circuit? RT013
RT009
RT018
RT007
RT015
RT012
No RT017
RT010
RT036
Inspect all the bolted
RT035
connection points in the main
RT011
low voltage distribution circuit.
RT022
RT031
RT032
RT029
T301
RT039
RT038
Is there any traces of burnt, Defective connection point. RT037
corrosion or a defect affecting Yes Replace any defective RT034
the quality of connection on connection point/system with RT016
the bolted connections? a good connection point. RT033
RT021
RT007
RT087
RT086
No RT027
Continued on next page RT024

622
Troubleshooting

No Continued from previous page

With an infrared thermometer

check the temperature of the
equalizer.

Turn OFF the truck, make sure

Is the equalizer Yes that the truck is not parked
temperature over
under the sun and wait 1 hour
100°C?
for the equalizer to cool down.

No
Is the error being No
raised again on Complete
further key cycles?

Yes

With an infrared thermometer

check the temperature of the
equalizer.

No Yes
Is the equalizer
overheating again?

Defective equalizer.
Replace equalizer.
With a multimeter, measure the voltage between the
following points:
Voltage equalizer Equalizer
Connector pin Connector pin

RT034 T1:1

623
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 No Voltage equalizer RT011
voltage in the range
Connector pin
of 24V?
RT034 RT011

RT012 RT013
Yes
RT012 RT013
Remove center tap cable and measure - Continuity : Resistance is less than or equal to 2ohms.
the LV_BT1 voltage with a multimeter.

Measure voltage of each battery. If

voltage is below 12V, charge batteries. Is there any evidence
If problem persists after charging of a continuity loss
batteries and voltage does not maintain No along the wiring?
over 12V, replace batteries.

Yes
Is the voltage lower No
than 12V? Defective harness.
Replace harness.

Yes

Try replacing LV_BAT1 and see if the

voltage eventually equalizes around 12V
on both batteries.

Is the voltage No Defective equalizer.

equalizing around 12V
Replace equalizer.
on both batteries?

Yes

Complete

624
Troubleshooting

A Disconnect blown fuse F1.

Replace fuse F1.
Restart the vehicle.

Yes
Did fuse F1 blow again
Disconnect fuse F1.
during test drive?

With a multimeter, check for short circuit between the No

following points:

RT014 Ground Complete

Connector pin
RT014 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Is there any proof of a

short-circuit to the ground Yes Defective wiring.
in the main low voltage Replace any defective wiring.
distribution circuit?

Measure voltage of each battery. If

voltage is below 12V, charge batteries.
If problem persists after charging
batteries and voltage does not maintain
over 12V, replace batteries.

625
Troubleshooting

B Disconnect blown fuse F2.

Replace fuse F2.
Restart the vehicle.

Disconnect fuse F2. Yes Did fuse F2 blow again

during test drive?

With a multimeter, check for short circuit between the

No
following points:

RT013 Ground
Connector pin
Complete
RT013 GND strip1

RT009 Ground
Connector pin
RT009 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Is there any proof of a

short-circuit to the ground Yes Defective wiring.
in the main low voltage Replace any defective wiring.
distribution circuit?

Measure voltage of each battery. If

voltage is below 12V, charge batteries.
If problem persists after charging
batteries and voltage does not maintain
over 12V, replace batteries.

626
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.

HMI displays or logs

Fault code F0108

Refer to the F0058 troubleshooting

tree.

627
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.
of range. due to defective LV connector
or harness. 2) Replace resistor R006.

2) Defective resistor R006 on 3) Replace temperature sensor.

temperature sensor circuit.

3) Defective temperature sensor.

A B C D E F
Connector C647

Connector C91

Connector C94
Connector C676

Circuit73

Connector C651.B

628
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 Yes Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No
With a multimeter, check for continuity between the
following points:
VCU C651.B C676P
Connector Connector
Pin 22 Pin 27

Pin 24 Pin 26

C676P C647s
Connector Connector
Pin F Pin E

C91S C94S
Connector Connector
Pin 27 Pin 2

Pin 26 Pin 1
VCU C651.B C647S
Connector Connector
Pin 60 Pin F

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

629
Troubleshooting

Continued from previous page

Is there any evidence of Yes Defective harness.

a continuity loss or a
Replace harness.
degraded connection ?

With a multimeter measure the

resistance on the ends of resistance
R006. Complete.

Does fault still

No appear after sensor
Is the measured resistance Defective R006.
replacement with
around 10K ohms ? Replace R006
correct part
number?

Yes Yes

Refer to PACCAR for sensor Contact Dana for further

investigation and replacement investigation.

630
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.
3) Update vehicle with the correct
3) Gear ratio or tire size recently parameters corresponding to
modified. the newly installed equipment.

The vehicle speed is estimated by the VCU based The rear axle speed is measured by the Traction
on measurements of the front and rear axle speed. If inverter, while the front axle speed is measured by
these two measurements are not in agreement, error the OEM brake controller. Error F0137 will be raised
F0137 will be raised. if one of these devices loses contact with the VCU.
Other possible causes include a failure of the motor
speed sensor or a calibration error.

631
Troubleshooting

HMI displays or logs

Fault code F0137

Does the HMI also display

Yes
‘’Brake Controller No contact’’ Refer to the corresponding error
or ‘’Traction inverter no troubleshooting tree.
contact’’?

Yes
Does the HMI also Refer to the F0099 troubleshooting
display F0099? tree.

Perform a test drive and

check the propulsion
diagnostic page.

Is the HMI showing 0 Yes

Defective traction inverter.
RPM on the motor speed
Replace traction inverter.
when driving?

Has the gear ratio or tire size Yes 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.
632
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.

633
Troubleshooting

HMI displays or logs

Fault code F0145

A Is the blower speed Yes

Set the blower speed to 1.
set to 0?

No Do you feel air No Refer to PACCAR for

blow from the
further investigation.
blower ?

Yes

Visually check that there is Yes No

Does the HMI still
coolant in the cab heater Complete
display the error ?
reservoir.

A
Is the coolant Yes
Refill the reservoir.
reservoir level low?

Does the HMI also display

F0143/F0053/F0054/F0055/ Yes Refer to the corresponding
F0133/F0134/F0135/F0136/ error troubleshooting tree.
’’Heater No contact’’?

Contact Dana for further

investigation.
634
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.
harness.

The cut loop is a section of LV wiring which can be

cut by first responders to shut down the HV system
in an emergency.

The cut loop consists of four wires. Three of these

supply the BMS and one is used by the VCU to
monitor the cut loop. Error F0147 indicates that only
the VCU wire is broken. If any of the BMS wires is
broken, the VCU will detect the loss of contact with
the BMS and will raise error F0058 instead. F0058
and F0147 should not be raised at the same time.

Connector C367P (pin)

Connector C40

Connector C367S (socket)

Connector C91

635
Troubleshooting

Connector C676

Circuit73

Connector C651.B

636
Troubleshooting

HMI displays or logs

Fault code F0147

Does the HMI also Yes Refer to the specific error

display F0058? troubleshooting tree.

Turn ignition OFF.

Inspect fuse F20 on 12V fuse box C14.

A
Is fuse F20 on 12V fuse box Yes
C14 blown or intermittent?

No
Disconnect connector C651.B from
VCU.
Disconnect connector C367
Disconnect connector C676.
Disconnect connector C40.
Remove fuse F20 in order to take
continuity measures from inside the
fuse box.

Refer to the connector investigation

subtree.

Continued on next page

637
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 C367P
Connector Connector
Pin 9 Pin 10

C40S 12V fuse box C14

Connector Terminal

Pin 27 C10

- Continuity : Resistance is less than or equal to 2ohms.

Contact Dana for further Is there any evidence of Yes Defective harness.
investigation. a continuity loss ? Replace harness.
No

638
Troubleshooting

Complete

A No

Remove and replace blown fuse Did fuse F20 blow again
Restart the vehicle.
F20 from 12V fuse box C14. during test drive?

Yes
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 Yes

investigation subtree. the connector integrity?

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

639
Troubleshooting

Continued from previous page

Is there any evidence of a Yes 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 No

Complete
during test drive?

Yes

Contact Dana for further

investigation.

640
Troubleshooting

F0148 - Overriding High Voltage Storage (ESS) Component

Error Description Possible Causes Possible Solutions

Supervisory controller has opened 1) Supervisory controller internal 1) Contact Dana.

contactors to shut down the ESS, error or software error.
but the cause of the shutdown was
not reported.

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.

HMI displays or logs

Fault code F0148

Contact Dana for further

investigation.

641
Troubleshooting

F0149 - Overriding Traction Control (Traction inverter) Component

Error Description Possible Causes Possible Solutions

Supervisory controller has opened 1) Supervisory controller internal 1) Contact Dana.

contactors to shut down the error or software error.
propulsion system, but the cause
of the shutdown was not reported.

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.

HMI displays or logs

Fault code F0149

Contact Dana for further

investigation.

642
Troubleshooting

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. software.

2) LV distribution or VCU-HMI 2) Troubleshoot specific error.

fault.
3) Resolve CAN communication
3) CAN communication problem. problem.

4) Accelerator pedal fault. 4) Replace accelerator pedal.

646
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 1/2/31

Does the HMI also Yes

display Refer to the corresponding error
‘’Supervisory controller troubleshooting tree.
No contact’’?

Yes Update the supervisory

Does the HMI also display
controller software following
‘’Please update software for
the procedure provided in the
CCU/FSVCU’’?
maintenance manual.

Yes
Does the HMI also Refer to the corresponding
display F0095 or F0104? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN D network.
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No
Yes

Contact Dana for further

investigation.
647
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
BMS. needed. software.

2) LV distribution or ESS fault. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

648
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code
3/4/5/6/7/8/9/10/11/19/20/21/
42/43/44/45/46/47/48/49

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Does the HMI also Yes

Refer to the ‘’BMS No contact’’
display ‘’BMS No
troubleshooting tree.
contact’’?

Yes
Does the HMI also Refer to the corresponding
display F0095? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN A network. Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN A actions prescribed in the
displayed?
network? subtree.

Yes
No

Contact Dana for further

investigation.
649
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.

3) CAN communication problem. 3) Resolve CAN communication

problem.

650
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 12

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Does the HMI also Yes

Refer to the ‘’BMS No contact’’
display ‘’BMS No
troubleshooting tree.
contact’’?

Yes
Does the HMI also Refer to the corresponding
display F0095? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN A and B networks.
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN A or CAN actions prescribed in the
displayed?
B networks? subtree.

No Yes

Contact Dana for further

investigation.

651
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. software.

2) DCDC or LV distribution fault. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

652
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 13/14/15/50

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Does the HMI also Yes

Refer to the ‘’DCDC No contact’’
display ‘’DCDC No
troubleshooting tree.
contact’’?

Yes
Does the HMI also Refer to the corresponding
display F0008 or F0095? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN D network.
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.
653
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. needed. software.

2) Propulsion fault. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

654
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code
16/24/32/33/37/38/39

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Does the HMI Yes Refer to the ‘’CAN No Contact with

also display ‘’Traction
traction inverter’’ troubleshooting
inverter No
tree.
contact’’?

Does the HMI also Yes

Refer to the corresponding
display F0099, F0098 or
troubleshooting tree.
F0097?

Refer to CAN investigation subtree

Investigate CAN B network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.
655
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. software.

2) VCU-HMI fault. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

The problem may have originated in OEM equipment

outside the scope of this troubleshooting guide.

656
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 17/41

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Does the HMI also Yes

display ‘’OEM No Refer to PACCAR further investigation.
contact’’ ?

Does the HMI also Yes

display ‘’Hazard Lamps Refer to PACCAR further investigation.
No contact’’?

Yes
Does the HMI also Refer to the F0050 troubleshooting
display F0050? tree.

No
Continued on next page

657
Troubleshooting

No Continued from previous page

Refer to CAN investigation subtree

Investigate CAN C network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN C actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

658
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.

3) CAN communication problem. 3) Resolve CAN communication

problem.

659
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 18

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Yes
Does the HMI also Refer to the corresponding
display F0057 or F0026? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN D and A network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D and A actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

660
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. needed. software.

2) VCU-HMI or LV distribution 2) Troubleshoot specific error.

fault.
3) Resolve CAN communication
3) CAN communication problem. problem.

661
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code
22/26/27/28/34/35/36

Does the HMI Yes

also display ‘’Supervisory Refer to the corresponding error
Controller No troubleshooting tree.
Contact’’?

Does the HMI also Yes Update the supervisory

display ‘’Please update controller software following
software for CCU/ the procedure provided in the
FSVCU’’? maintenance manual.

Yes
Does the HMI also Refer to the F0095 troubleshooting
display F0095? tree.

Refer to CAN investigation subtree

Investigate CAN D network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.
662
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. software.

2) LV distribution fault. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

663
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 23

Yes Update the supervisory

Does the HMI also display
controller software following
‘’Please update software for
the procedure provided in the
CCU/FSVCU’’?
maintenance manual.

Yes
Does the HMI also Refer to the F0095 troubleshooting
display F0095? tree.

Refer to CAN investigation subtree

Investigate CAN B network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN B actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

664
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.

2) CAN communication problem. 2) Resolve CAN communication

problem.

The problem may have originated in OEM equipment

outside the scope of this troubleshooting guide.

665
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 25/40

Yes Update the supervisory

Does the HMI also display
controller software following
‘’Please update software for
the procedure provided in the
CCU/FSVCU’’?
maintenance manual.

Does the HMI also

display ‘’OEM No
Yes Contact’’ ?

Does the HMI also Yes

display ‘’Gear Shifter No Refer to PACCAR further investigation.
contact’’?

Refer to CAN investigation subtree

Investigate CAN C network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN C actions prescribed in the
displayed?
network? subtree.

Yes
No

Contact Dana for further

investigation.
666
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. 2) Troubleshoot specific error.

3) CAN communication problem. 3) Resolve CAN communication

problem.

667
Troubleshooting

HMI displays or logs

Fault code F0156 and
Signal validity code 29/30

Yes Update the supervisory

Does the HMI also display
controller software following
‘’Please update software for
the procedure provided in the
CCU/FSVCU’’?
maintenance manual.

Yes
Does the HMI also Refer to the corresponding
display F0095? troubleshooting tree.

Refer to CAN investigation subtree

Investigate CAN D network
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

668
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.

669
Troubleshooting

Supervisory Controller no contact

Error Description Possible Causes Possible solutions

VCU has not received any CAN 1) LV distribution fault. 1) Troubleshoot specific error.
message from the Supervisory
controller within a specified time 2) CAN communication problem. 2) Resolve CAN communication
interval. problem.

No Contact fault messages appear on the HMI Note: The Supervisory controller and VCU
display and remain while the fault is active. are both connected to CAN A, B, C and D
Historical No Contact fault messages can be found networks, but communication between the
in the HMI logs by selecting the MC43[2]log. Supervisory controller and VCU occurs on
CAN D.

HMI displays
“Supervisory Controller No contact.”

Yes
Does the HMI also Refer to the F0095 troubleshooting
display F0095? tree.

Refer to CAN investigation subtree

Investigate CAN D network.
Complete

Were you able to find a Yes Repair according to the

Is the error code still
problem in the CAN D actions prescribed in the
displayed?
network? subtree.

No Yes

Contact Dana for further

investigation.

670
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.
radiator, pump, and fans.
Powertrain Coolant Pump
Component descriptions
The Powertrain Coolant Pump circulates coolant
Cooling Circuit through the cooling circuit. It is powered by 24V low
voltage and communicates through the CAN
The cooling circuit runs through each component network.
connected to the cooling system. It consists of a
reservoir, radiator, pump, and associated coolant Cooling Fans
lines. Equipment is connected to the coolant lines in
three parallel branches. One branch runs through The cooling fans circulate air through the radiator to
the propulsion motor and Traction inverter, one carry away waste heat from the coolant. The same
branch runs through the DCDC and air brake fans are also used by the HVAC system to circulate
compressor, and one runs through the OBC. air through the condenser.

671
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. 3) Replace 24V fuse F16.

4) Loss of continuity due to 4) Replace LV connector or

defective LV connector or harness per Service Manual.
harness.
5) Resolve cooling circuit
5) Problem with the cooling problem.
circuit (leak, low coolant, etc.).
6) Replace Powertrain Coolant
6) Powertrain Coolant Pump Pump.
internal failure.

Connector C81

672
Troubleshooting

HMI displays or logs

Fault code F0059

Check the HMI for other faults.

Does the HMI also

display “F0008 - 12V/ Yes 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.
operating on the truck. box C20.

Is fuse F6 blown or
intermittent?
Yes
A
No

Inspect fuse F16 in the 24V fuse

box C20.
Is fuse F16 blown or
intermittent?
Yes
B

Disconnect connector C81 from

coolant pump.
Refer to connector
Remove fuse F6 and F16 in order
investigation subtree.
to take continuity measures
from inside the fuse box.

Continued on next page

673
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
Coolant Pump C81 24V fuse box C20
Connector pin Terminal

Pin 3 A6

Coolant Pump C81

Ground
Connector pin
Pin 2 Ground

Coolant Pump C81 24V fuse box C20

Connector pin Terminal
Pin 4 C6

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Refer to the cooling

Investigation subtree.

Was any root cause found Yes

Complete
in the cooling circuit?

Contact DANA for further

investigation.
674
Troubleshooting

Complete
A No

Replace fuse F6 on 24V fuse box

Disconnect blown fuse F6 from Did fuse F6 blow again
C20.
24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F6 from 24V fuse
coolant pump.
box C20.

Defective connector.
Is there any Replace the connector as
problem with the Yes described in the “Wire Harness
Refer to connector investigation subtree.
connector Connector Identification,
integrity? Location, and Service Chart” in
the Service Manual

With a multimeter, check for short circuit between

the following points: No

Coolant Pump C81

Ground
Connector pin
Pin 3 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any
evidence of a short Yes Defective harness.
circuit within the Replace harness.
harness ?

Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again No
Complete
Restart the vehicle. during test drive?

Yes

Contact Dana for further

investigation.

675
Troubleshooting

Complete
B No

Replace fuse F16 on 24V fuse

Disconnect blown fuse F16 Did fuse F16 blow again
box C20.
from 24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F16 from 24V fuse
coolant pump.
box C20.

Defective connector.
Is there any Replace the connector as
problem with the Yes described in the “Wire Harness
Refer to connector investigation subtree.
connector Connector Identification, Location,
integrity? and Service Chart” in the Service
Manual

With a multimeter, check for short circuit between

the following points: No
Coolant Pump C81
Ground
Connector pin
Pin 4 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any Yes Defective harness.

evidence of a short circuit
Replace harness.
within the harness ?

Replace fuse F16 on 24V fuse box No

Did fuse F16 blow again
C20. Complete
during test drive?
Restart the vehicle.

Yes

Contact Dana for further

investigation.
676
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. 3) Replace 24V fuse F16.

4) Loss of continuity due to 4) Replace LV connector or

defective LV connector or harness per Service Manual.
harness.
5) Replace Powertrain Coolant
5) Powertrain Coolant Pump Pump.
internal failure.

Note: It is unlikely that error F0060 would

result from a problem with the cooling circuit.
However, the troubleshooting tree includes a
check of the coolant level to quickly rule out
a major cooling circuit problem.

Connector C81

677
Troubleshooting

HMI displays or logs

Fault code F0060

Check the HMI for other faults.

Does the HMI also

display “F0008 - 12V/ Yes 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.
operating on the truck. box C20.

A
Is fuse F6 blown or Yes
intermittent?

Inspect fuse F16 in the 24V fuse

box C20.
Is fuse F16 blown or
intermittent?
Yes
B

Disconnect connector C81 from

coolant pump.
Refer to connector
Remove fuse F6 and F16 in order
investigation subtree.
to take continuity measures
from inside the fuse box.

Continued on next page

678
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
Coolant Pump C81 24V fuse box C20
Connector pin Terminal

Pin 3 A6

Coolant Pump C81

Ground
Connector pin
Pin 2 Ground

Coolant Pump C81 24V fuse box C20

Connector pin Terminal
Pin 4 C6

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace harness.

Check the coolant level in the

reservoir.

Continued on next page

679
Troubleshooting

Continued from previous page

Yes Check the cooling circuit for

Is the coolant level low?
leaks.

Is there any leak in the Yes Repair the leak and refill
cooling circuit? coolant.

Refer to the CAN Investigation

subtree. Refill coolant.
Investigate CAN D network.

No
Is the error still raised? Complete

Yes

Contact Dana for further

investigation.

680
Troubleshooting

Complete
A No

Replace fuse F6 on 24V fuse box

Disconnect blown fuse F6 from Did fuse F6 blow again
C20.
24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F6 from 24V fuse
coolant pump.
box C20.

With a multimeter, check for short circuit between

the following points: No

Coolant Pump C81

Ground
Connector pin
Pin 3 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any
evidence of a short Yes Defective harness.
circuit within the Replace harness.
harness ?

Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again No
Complete
Restart the vehicle. during test drive?

Yes

Contact Dana for further

investigation.

681
Troubleshooting

Complete
B No

Replace fuse F16 on 24V fuse

Disconnect blown fuse F16 Did fuse F16 blow again
box C20.
from 24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F16 from 24V fuse
coolant pump.
box C20.

Defective connector.
Is there any Replace the connector as
problem with the Yes described in the “Wire Harness
Refer to connector investigation subtree.
connector Connector Identification, Location,
integrity? and Service Chart” in the Service
Manual

With a multimeter, check for short circuit between

the following points: No
Coolant Pump C81
Ground
Connector pin
Pin 4 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any Yes Defective harness.

evidence of a short circuit
Replace harness.
within the harness ?

Replace fuse F16 on 24V fuse box No

Did fuse F16 blow again
C20. Complete
during test drive?
Restart the vehicle.

Yes

Contact Dana for further

investigation.
682
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.

HMI displays or logs

Fault code F0109

Inspect the wiring going to the

powertrain coolant level sensor
for short circuits.

Is there any evidence Yes Defective harness.

of a short circuit
Replace harness.
within the harness?

Defective coolant level sensor.

Replace coolant level sensor.

683
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. coolant level sensor due to
defective LV connector or
harness.

HMI displays or logs

Fault code F0110

Inspect the wiring going to the

powertrain coolant level sensor
for continuity loss.

Is there any evidence Yes Defective harness.

of a continuity loss
Replace harness.
within the harness?

Defective coolant level sensor.

Replace coolant level sensor.

684
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. 2) Replace 24V fuse F6.
3) Loss of continuity due to
defective LV connector or 3) Replace LV connector or
harness. harness per Service Manual.

4) Powertrain Coolant Pump 4) Replace Powertrain Coolant

internal failure. Pump.

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.

Connector C81

685
Troubleshooting

HMI displays
“Powertrain cooling pump
No contact.”

Check the HMI for other faults.

Does the HMI also

display “F0008 - 12V/ Yes 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.
operating on the truck. box C20.

A
Is fuse F6 blown or Yes
intermittent?

B
Inspect fuse F16 in the 24V fuse Is fuse F16 blown or Yes
box C20. intermittent?

Disconnect connector C81 from

coolant pump.
Refer to connector
Remove fuse F6 and F16 in order
investigation subtree.
to take continuity measures
from inside the fuse box.

Continued on next page

686
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
Coolant Pump C81 24V fuse box C20
Connector pin Terminal

Pin 3 A6

Coolant Pump C81

Ground
Connector pin
Pin 2 Ground

Coolant Pump C81 24V fuse box C20

Connector pin Terminal
Pin 4 C6

- Continuity : Resistance is less than or equal to

2ohms.

Is there any evidence of Yes Defective harness.

continuity loss? Replace or repair harness.

Refer to the CAN Investigation

No
subtree. Is the error still raised? Complete
Investigate CAN D network.

Yes

Contact Dana for further

investigation.

687
Troubleshooting

Complete
A No

Replace fuse F6 on 24V fuse box

Disconnect blown fuse F6 from Did fuse F6 blow again
C20.
24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F6 from 24V fuse
coolant pump.
box C20.

With a multimeter, check for short circuit between

the following points: No

Coolant Pump C81

Ground
Connector pin
Pin 3 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any
evidence of a short Yes Defective harness.
circuit within the Replace harness.
harness ?

Replace fuse F6 on 24V fuse box C20. Did fuse F6 blow again No
Complete
Restart the vehicle. during test drive?

Yes

Contact Dana for further

investigation.

688
Troubleshooting

Complete
B No

Replace fuse F16 on 24V fuse

Disconnect blown fuse F16 Did fuse F16 blow again
box C20.
from 24V fuse box C20. during test drive?
Restart the vehicle.

Turn ignition OFF and

Disconnect connector C81 from Yes
disconnect F16 from 24V fuse
coolant pump.
box C20.

Defective connector.
Is there any Replace the connector as
problem with the Yes described in the “Wire Harness
Refer to connector investigation subtree.
connector Connector Identification, Location,
integrity? and Service Chart” in the Service
Manual

With a multimeter, check for short circuit between

the following points: No
Coolant Pump C81
Ground
Connector pin
Pin 4 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any Yes Defective harness.

evidence of a short circuit
Replace harness.
within the harness ?

Replace fuse F16 on 24V fuse box No

Did fuse F16 blow again
C20. Complete
during test drive?
Restart the vehicle.

Yes

Contact Dana for further

investigation.
689
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
operators for monitoring purposes. The modem manages wireless communications
between the telemetry module and the remote
Component descriptions server. It is powered by 12V low voltage.

Telemetry Timed Relay

The telemetry module collects data from the vehicle The timed relay powers on the telemetry module and
systems and transmits it to remote servers via the modem at fixed intervals to collect and transmit data.
modem. It is powered by 12V low voltage and
communicates via the CAN B network.

690
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.
interval. 2) Troubleshoot specific error.
3) Blown 12V fuse F14.
3) Replace 12V fuse F14.
4) Blown MPDM fuse F14.
4) Replace MPDM fuse F14.
5) Loss of continuity due to
defective LV connector or 5) Replace LV connector or
harness. harness per Service Manual.

6) Defective timed relay 2. 6) Replace timed relay 2.

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.

Connector C12 (gray)

Connector C92

691
Troubleshooting

Connector C416 Connector C661

Connector C699P (pin)

Connector C621

Connector C699S (socket)

692
Troubleshooting

HMI displays
“Telemetry No Contact”
OR
Fleet owner is receiving empty
telemetry data files

Refer to CAN investigation subtree

Investigate CAN B network

Complete

Were you able to find a Yes Take the actions Is the error code still
problem in the CAN B
prescribed in the subtree. displayed?
network?

No Yes

Yes
Does the HMI also Refer to error F0095
display error troubleshooting tree.
F0095?

Inspect fuse F14 on 12V fuse box

C14 and fuse F14 on MDPM.

Is fuse F14 on 12V fuse Yes

B Yes Is fuse F14 on MPDM
blown or intermittent?
No
box C14 blown or
intermittent?
A

No
Continued on next page

693
Troubleshooting

No 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.

Is there any Defective connector.

problem with the Yes Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No
With a multimeter, check for continuity between the
following points:
12V fuse box C14 C92S
Terminal Connector pin
C4 Pin 7

C621P C699S
Connector pin Connector pin

Pin 7 Pin 1

C416S.HED C699P.HED
Connector pin Connector pin

Pin 6 Pin 1

Pin 8 Pin 11

C12 C92S
Connector pin Connector pin

Pin F Pin 11
C661S C92P
Connector pin Connector pin

Pin 11 Pin 11
C661S C669S
Connector pin Connector pin

Pin 10 Pin 1
C621P C661S
Connector pin Connector pin

Pin 7 Pin 8

Pin 11 Pin 11

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page 694

Troubleshooting

Continued from previous page

Yes
Is there any evidence of Defective harness.
a continuity loss ? Replace harness.

Replace timer relay 2.

Turn ignition ON.

Does the HMI still No

display ‘’Telemetry No Complete
Contact’’?

Yes

Contact Dana for further

investigation.

695
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 No

Complete
during a test drive?

Yes

Turn ignition OFF and

disconnect F14 from 12V fuse
box C14.

Disconnect connector C416 from

FleetManagementKit.

Refer to the connector

investigation subtree.

Continued on next page

696
Troubleshooting

Continued from previous page

With a multimeter, check for short circuit between

the following points:
12V fuse box C14 C4
Ground
Connector pin

PC4 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any evidence Yes

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?
No

Yes

Contact Dana for further

investigation.

697
Troubleshooting

Disconnect blown fuse F14 from

MPDM.

Replace fuse F14 in MPDM.

Restart the vehicle.

Did fuse F14 blow again No

Complete
during a test drive?

Yes

Turn ignition OFF and

disconnect F14 from MPDM.

Disconnect connector C12 from MPDM.

Disconnect connector C416 from
FleetManagementKit.

Refer to the connector investigation

subtree.

Is there any Defective connector.

problem with the Yes Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

Continued on next page No

698
Troubleshooting

No Continued from previous page

With a multimeter, check for short circuit between

the following points:
MPDM C12
Ground
Connector pin

Pin F Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Is there any evidence Yes

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?
No

Yes

Contact Dana for further

investigation.

699
Troubleshooting

ePTO System
The electric power take-off (ePTO) system provides
an electrical power output which can be used to
operate aftermarket onboard accessories.

700
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.
defective LV connector or
harness. 4) Replace HV harness.

4) Loss of continuity due to

defective HV connector or
harness.

Note: Connectors may vary from what is

shown depending on ePTO configuration.

Connector C15S (socket)

Connector C6
(orientation depends on ePTO configuration)
Connector C15P (pin)

701
Troubleshooting

3
4 Connector C722
Connector C101

3
4 Connector C713

702
Troubleshooting

HMI displays or logs

Fault code F0015

Does the HMI also Yes

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 Yes

box C14 blown or
intermittent?
A

Disconnect connector C6 from ePTO.

Disconnect connector C15.
Remove fuse F11 in order to take
continuity measures from inside the
fuse box.

Refer to connector investigation

subtree.

Continued on next page

703
Troubleshooting

Continued from previous page

Is there any Defective connector.

Yes
problem with the Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No
With a multimeter, check for continuity between the
following points:
12V fuse box C14 C15S
Terminal Connector pin
C1 Pin 4

C15P_B ePTO C6
Connector pin Connector pin

Pin 4 Pin L1

Pin 4 Pin M1

Pin 4 Pin J1

Pin 9 Pin L4

Pin 9 Pin M4
C15S C101 ground
Connector pin Connector pin
Pin 9 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

No Is there any Yes

Defective harness.
evidence of a
Replace harness.
continuity loss ?

WARNING: Electrical hazard.

Follow Safety Warnings and High

Voltage Shutdown Procedures
defined in the Service Manual
and Diagnostic Guide.

Continued on next page

704
Troubleshooting

Continued from previous page

Disconnect connector C713 from

HV junction box.
Disconnect connector C722 from
ePTO.

Refer to connector investigation

subtree.

Is there any
Yes
problem with the Defective connector.
connector Replace harness.
integrity?

With a multimeter, check for continuity between the

following points:
HV JB C713P ePTO C722P
Connector pin Connector pin
Pin 2 Pin 1

Pin 1 Pin 2
RT045 RT044
Connector pin Connector pin
RT045 RT044

- Continuity : Resistance is less than or equal to 2ohms.

Is there any Yes

Defective harness.
evidence of a
Replace harness.
continuity loss ?

Contact Dana for further

investigation.

705
Troubleshooting

Complete

A No

Replace fuse F11 on 12V fuse

Disconnect blown fuse F11 from Did fuse F11 blow again
box C14.
12V fuse box C14. during a test drive?
Restart the vehicle.

Yes

Turn ignition OFF and

Refer to connector Disconnect connector C6 from
disconnect F11 from 12V fuse
investigation subtree. ePTO.
box C14.

Is there any Defective connector.

Yes
problem with the Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No Defective harness.
Replace harness.
With a multimeter, check for short circuit between
Yes
the following points:
12V fuse box C14 C1
Ground
Connector pin
Is there any evidence
Pin C1 Ground of a short circuit
within the harness?
-LV short: Resistance measurement is less than 100k-
ohms.
-Inspect all connectors and wires between the two No
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?
Yes

Complete
706
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.
3) Troubleshoot specific error.
3) Analog HVIL fault.

The purpose of the HVIL is to provide a warning if

any HV connector is unplugged without the HV
distribution being safely ended. The ePTO monitors
continuity between the HVIL pins on its HV
connector (C722). If this connector is unplugged
unsafely, the HVIL will be broken and the ePTO will
send an error message via CAN.

Depending on the ePTO configuration, the ePTO HV

connector (C722) may also be connected to the
analog HVIL. This a single circuit that runs through
various HV connectors on the vehicle. If a connector
is unplugged, the HVIL will be broken and the VCU 3
will detect the loss of signal voltage on the circuit. If
the analog HVIL is broken, one or more of the errors 4
F0061, F0062, or F0063 will be raised. Connector C722

Note: Connectors may vary from what is

shown depending on ePTO configuration.

707
Troubleshooting

HMI displays or logs

Fault code F0139

Does the HMI also display Yes Refer to the Analog HVIL
F0063/F0062/F0061? investigation subtree.

Could you find any defect in Yes Repair as prescribed in

the HVIL analog circuit? the in subtree.

WARNING: Electrical hazard.

No
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

708
Troubleshooting

Continued from previous page

Disconnect connector C722

from the ePTO.

Refer to connector
investigation subtree.

Is there any problem with Yes 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

Pin 3 Pin 4

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Defective ePTO.
Replace ePTO.

709
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.
3) Replace 12V fuse F11.
4) Loss of continuity due to
defective LV connector or 4) Replace LV connector or
harness. harness per Service Manual.

No Contact fault messages appear on the HMI Note: Connectors may vary from what is
display and remain while the fault is active. shown depending on ePTO configuration.
Historical No Contact fault messages can be found
in the HMI logs by selecting the MC43[2]log.

Connector C15S (socket)

Connector C6
(orientation depends on ePTO configuration)

Connector C15P (pin)

710
Troubleshooting

Connector C101

711
Troubleshooting

HMI displays
“ePTO No contact.”

Refer to CAN investigation subtree

Investigate CAN D network

Complete

Were you able to find a Yes Take the actions Is the error code still
problem in the CAN D
prescribed in the subtree. displayed?
network?

No Yes

Yes
Does the HMI also Refer to error F0095
display error troubleshooting tree.
F0095?

Is fuse F11 on 12V fuse Yes

Inspect fuse F11 on 12V fuse box
C14.
box C14 blown or
intermittent?
A

Disconnect connector C6 from ePTO.

Disconnect connector C15.
Refer to connector investigation
Remove fuse F11 in order to take
subtree.
continuity measures from inside the
fuse box.

Continued on next page

712
Troubleshooting

Continued from previous page

Is there any Defective connector.

Yes
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
Terminal Connector pin
C1 Pin 4

C15P_B ePTO C6
Connector pin Connector pin

Pin 4 Pin L1

Pin 4 Pin M1

Pin 4 Pin J1

Pin 9 Pin L4

Pin 9 Pin M4
C15S C101 ground
Connector pin Connector pin
Pin 9 Pin 2

- Continuity : Resistance is less than or equal to 2ohms.

Yes
Is there any evidence of Defective harness.
a continuity loss ? Replace harness.

Contact Dana for further

investigation.

713
Troubleshooting

Complete

A No

Replace fuse F11 on 12V fuse

Disconnect blown fuse F11 from Did fuse F11 blow again
box C14.
12V fuse box C14. during a test drive?
Restart the vehicle.

Yes

Turn ignition OFF and

Refer to connector Disconnect connector C6 from
disconnect F11 from 12V fuse
investigation subtree. ePTO.
box C14.

Is there any Defective connector.

Yes
problem with the Replace the connector as described in the “Wire
connector Harness Connector Identification, Location, and
integrity? Service Chart” in the Service Manual

No Defective harness.
Replace harness.
With a multimeter, check for short circuit between
the following points: Yes
12V fuse box C14 C1
Ground
Terminal
Is there any evidence
Pin C1 Ground of a short circuit
within the harness?
-LV short: Resistance measurement is less than 100k-
ohms.
-Inspect all connectors and wires between the two No
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?
Yes

Complete

714
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. The technician should refer to original troubleshooting tree.
these subtrees when instructed during

715
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.

The purpose of the HVIL is to provide a warning if

any HV connector is unplugged without the HV
distribution being safely ended. Some onboard
equipment, such as the DCDC, A/C compressor, and
TMS, monitor their HV connectors locally and alert
the VCU via CAN if a connector is unplugged
(software HVIL). In contrast, the analog HVIL is a
physical circuit that runs through various HV
connectors on the vehicle. If a connector is Connector C5
unplugged unsafely, the HVIL will be broken and the
VCU will detect the loss of signal voltage on the
circuit.

Because the analog HVIL is a single series circuit,

the VCU will detect the presence of a discontinuity
but not its location. The technician should use this
troubleshooting subtree.

Connector C15S (socket)

Connector C3

Connector C15P (pin)

716
Troubleshooting

Connector C91

Connector C22

Connector C202

Connector C40

Connector C300

Connector C73

717
Troubleshooting

Connector C367P (pin) Connector C367S (socket)

Connector C676

Circuit73

Connector C651.B

718
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. Yes
Is fuse F3 blown or
intermittent? A

Disconnect connector C5
from the HV junction box.

Install a jumper in connector

C5 from pin 1 to pin 6

Turn ignition ON.

With a multimeter, check for continuity between the

following points:
C300P HV JB C300P HV JB
B
No Is the error still being Yes
Connector pin Connector pin
raised?
Pin 1 Pin 6

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

719
Troubleshooting

Continued from previous page

No
Is there any evidence Contact Dana for further
of a continuity loss? investigation.

Yes

Perform a wiggle test on all connectors

connected to the HV junction box:
- Move the connector side to side gently and
check if the continuity is restored after each
one,
- Ensure all cables are connected properly,
- Ensure all secondary locks are engaged,
- Ensure no visual damage on the connectors
and the harness

Is the continuity restored Yes

after performing a wiggle Complete
test on all connectors?

Defective HV junction box.

Replace HV junction box.

720
Troubleshooting

A 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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C5 from the
disconnect F3 from 12V fuse box
investigation subtree. HV junction box.
C14.

With a multimeter, check for short circuit between the

following points:
A3 12V fuse box C14 Ground
Connector pin

A3 GND strip1
C5 HV JB Ground
Connector pin
Pin 6 GND strip1

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two test
points of the harness ends.

Continued on next page

721
Troubleshooting

Continued from previous page

Is there any evidence of a

Defective harness.
short circuit on one of these
Replace defective segment.
segments? Yes

With a multimeter, perform a

continuity test between:
- Connector C300P pin 1 and casing
and ground.
- Connector C300P pin 6 and casing
and ground.

Is there any evidence of a

Yes Defective harness.
short circuit to the ground or
Replace harness.
the HV junction casing?

Replace fuse F3 on 12V fuse box

C14.
Restart the vehicle.

Does fuse F3 blow again No

Complete
during a test drive?

Yes

Defective HV junction box.

Replace HV junction box.

722
Troubleshooting

B
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.

No
With a multimeter, check for continuity between the
following points:
C5 HV JB 12V fuse box C14
Connector pin Terminal
Pin 1 A3
C5 HV JB C3 MCU
Connector pin Connector pin
Pin 6 Pin J
C3 MCU C22 OBC
Connector pin Connector pin
Pin K Pin 1
C22 OBC C73 HTR
Connector pin Connector pin
Pin 2 Pin 5
C73 HTR C40S
Connector pin Connector pin
Pin 7 Pin 33
C40P C367S
Connector pin Connector pin
Pin 33 Pin 5

- Continuity : Resistance is less than or equal to 2ohms.

Continued on next page

723
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:

C367P C202 U5
Connector pin Connector pin
Pin 5 Pin 2
C202 compressor C367P
Connector pin Connector pin
Pin 8 Pin 6
C367S C40P
Connector pin Connector pin
Pin 6 Pin 34
C40S C15S
Connector pin Connector pin
Pin 34 Pin 1
C15P C15P
Connector pin Connector pin
Pin 1 Pin 12
C15S C91S
Connector pin Connector pin
Pin 12 Pin 9
C676P C651.B VCU
Connector pin Connector pin
Pin 9 Pin 28

- Continuity : Resistance is less than or equal to 2ohms.

Yes
Is there any evidence Defective harness.
of a continuity loss? Replace harness.

Contact Dana for further

investigation.

724
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. To locate
should return to the original troubleshooting tree. the correct devices, connectors, and pins on each
network, please see the tables below.
The vehicle has five CAN networks, designated CAN
A through CAN E, which each connect a different set
of devices.

725
Troubleshooting

CAN A

Devices and Connectors

CAN connector CAN High pin CAN Low pin

Diagnostics C410 1 12
VCU C651.A 17 1
A/C compressor C71 2 1
SB C44 4 5
U8 C203 3 4
U5 C202 7 3
PNOVO+ C53 E4 F4
Termination resistor 1 C53.A A B
Termination resistor 2 C649.A A B

Connector C44
Connector C53.A

Connector C53 Connector C71

726
Troubleshooting

Connector C202

Connector C410

Connector C203

Connector C649.A

Connector C651.A

727
Troubleshooting

CAN B

Devices and Connectors

CAN connector CAN High pin CAN Low pin

Diagnostics C410 2 11
VCU C651.A 18 2
HMI C650.A 8 5
TELEMETRY C416 6 8
Traction inverter C3 D C
OBC C22 8 7
CHILLER C45 1 2
PNOVO+ C53 J4 K4
Termination resistor 1 C53.B A B
Termination resistor 2 C649.B A B

Connector C3 Connector C45

Connector C53

Connector C22

728
Troubleshooting

Connector C53.B Connector C649.B

Connector C410

Connector C650.A

Connector C416

729
Troubleshooting

Connector C651.A

730
Troubleshooting

CAN C

Devices and Connectors

CAN connector CAN High pin CAN Low pin

Diagnostics C410 3 10
VCU C651.A 19 3
HMI C650.A 9 4
DIP D366 16 15
DIP D366 7 6
VIC D358 C15 C15
EBS D376 A3 A1
PRNDL P101 8 15
CND_FAN1 C82 5 10
CND_FAN2 C89 5 10
CN_LN C72 3 2
MPDM C10 6 12
OEM_RADAR OEM_RADAR H L
PNOVO+ C53 G4 H4
Termination resistor 1 C53.C A B
Termination resistor 2 C649.C A B

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

731
Troubleshooting

Connector C72

Connector C410

Connector C82

Connector C649.C

Connector C89

Connector C650.A

732
Troubleshooting

Connector C651.A

733
Troubleshooting

CAN D

Devices and Connectors

CAN connector CAN High pin CAN Low pin

Diagnostics C410 4 9
VCU C651.B 17 1
HMI C650.A 10 3
CLD_PMP C80 1 6
EPTO1 C6 A2 C2
EHPS_INV C34 6 7
EHPS_INV C34 3 4
DCDC C84 5 6
PNOVO+ C53 C4 D4
Termination resistor 1 C53.D A B
Termination resistor 2 C649.D A B

Connector C53
Connector C6

Connector C53.D
Connector C34

734
Troubleshooting

Connector C80
Connector C649.D

Connector C84

Connector C650.A

Connector C410

735
Troubleshooting

Circuit73

Connector C651.B

736
Troubleshooting

CAN E

Devices and Connectors

CAN connector CAN High pin CAN Low pin

Diagnostics C410 5 8
VCU C651.B 18 2
HMI C650.A 11 2
Termination resistor 1 C446 A B
Termination resistor 2 C649.E A B

Connector C649.E

Connector C410

Connector C446

Connector C650.A

737
Troubleshooting

Circuit73

Connector C651.B

738
Troubleshooting

CAN network investigation.

Inspect the connector terminals of all

Refer to the subtree description. connectors on the suspect CAN
Locate the connectors and pins network for traces of corrosion or
corresponding to each CAN. improper connection. Replace
damaged or corroded connectors.
Turn ignition OFF and turn LOTO
switch OFF.
With a multimeter measure the
resistance between CAN_H and CAN_L
anywhere on the suspect CAN
network while the vehicle is not
operating and the LOTO switch is OFF.

Is the measured No Is the measured

B
Yes
resistance greater than resistance less than
68 ohms? 54 ohms?

Yes No

A Turn on the LOTO

switch.

Individually disconnect the LV power from

each device on the suspect CAN network.
Cycle the ignition and check fault codes
after each to determine when the fault is
no longer present.

No Could you find a system/device

causing the CAN network fault?

Contact Dana for Yes

further investigation.

739
Troubleshooting

A termination resistor may be defective, or

not connected to the network. Is resistance Yes
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

No Is resistance
Replace termination
across harness pins
resistor 2.
108 - 132 ohms?

Yes

No
Defective harness.
Is the problem resolved?
Replace harness.

Yes

Complete

740
Troubleshooting

There are too many termination

resistors on the network.
Is resistance across Yes
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.
No

Replace
termination resistor 1

No Is resistance across
Replace
the harness pins
termination resistor 2.
108-132 ohms?

Yes

Reconnect connectors, turn

on LOTO switch and cycle the
ignition to ready mode.

Is the fault still present? Complete

Yes
Continued on next page

741
Troubleshooting

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.

Yes
Is there a parasitic Defective harness.
resistance found? Replace harness.

Contact Dana for

further investigation

742
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

743
Troubleshooting

Connector integrity Inspection

Fully plug in the connector,

Are primary and No ensuring that primary and
secondary locks fully
secondary locks are locked
locked?
correctly.

Yes

Yes Is the initial code you

were troubleshooting
still being raised?

Complete.

Are any of the

connector pins in the Yes
suspect device connector
bent, broken, or
recessed?

No Is the device connector

an Amphenol Type
connector?

Yes

Does the whole

Yes

A
No connector move toward the
Defective device.
inside of the device while
Replace device.
pushing firmly on the base
of the connector?

744
Troubleshooting

Is there evidence of a foreign

material in one of the connectors, a Yes
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.
No

Using a multimeter, validate the

Is there evidence
continuity between both ends of the No
of damaged, corroded, or
harness connector for each pin.
burnt pins in the harness
Continuity: Resistance is less than or
connector(s)?
equal to 2ohms.

Yes

Defective connector.
Yes
Is there evidence of a Replace the connector as described in the “Wire
continuity loss? Harness Connector Identification, Location, and
Service Chart” in the Service Manual

Using a multimeter, validate that there Is there evidence of a Yes

is no unwanted short-circuits between short circuit or burnt pins
each pins of the connector. in the connector?

Reconnect the harness to

the subsystem.

745
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 Yes Refer to the corresponding error
or pump/condenser troubleshooting tree.
fan no contact?

Locate the coolant pump.

Is any unusual sound Yes Bleed the pump.

coming from the coolant
Refill coolant as needed.
pump?

Yes
Is the issue resolved? Complete

While the pump is running,

check the coolant level in the Replace coolant pump.
reservoir.

Continued on next page

746
Troubleshooting

Continued from previous page

Yes
Is the coolant level low?

Turn ignition OFF.

While the pump is off, check the

coolant level in the reservoir.

Yes Check the cooling circuit for

Is the coolant level low?
leaks.

Inspect each hose in the cooling Repair the leak and refill Yes Is there any leak in the
circuit. coolant. cooling circuit?

Yes
Connect, repair, or replace the
Is any hose kinked, pinched,
hose. Refill coolant.
or loose?
Refill coolant if necessary.

Complete

747
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

748
Troubleshooting

Heating circuit investigation

If the heater was used recently,

wait for components to cool
down.

Is the fluid in the No Drain and flush heating circuit.

heating circuit the
Refill with correct fluid.
correct specification?

Yes

Check the fluid level in the

heating circuit reservoir.

Yes Check the heating circuit for

Is the fluid level low?
leaks.

Is there any leak in the Yes

Repair the leak and refill fluid.
heating circuit?

Inspect each section of the

Refill fluid.
heating circuit.

Continued on next page

749
Troubleshooting

Continued from previous page

Yes 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.

A
Does the heater pump run No
when requested?

Yes

Does fluid flow out of Yes

the reservoir when the Complete
pump is running?

Disconnect hose from pump

outlet. Pinch off hose.

Is the pump outlet Yes Clear obstruction, reconnect

visibly obstructed? hose, and refill fluid as needed.

No
Continued on next page

750
Troubleshooting

No Continued from previous page

Bleed the heater pump by using

the service interface to activate
the pump. A
No

Does fluid flow out of

No Check for obstructions between Is the heating circuit
the outlet when the
the reservoir and pump. obstructed?
pump is running?

Yes Yes

Reconnect the hose to the pump Clear obstruction, reconnect

outlet. Refill fluid as needed. hoses, and refill fluid as needed.

Is the problem Yes

Complete
resolved?

Disconnect the heating circuit

one section at a time and check
for obstructions.

Is the heating circuit Yes Clear obstruction, reconnect

obstructed? hoses, and refill fluid as needed.

Contact DANA for further

investigation.

751
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.

B
Is fuse F15 blown or Yes
intermittent?

Disconnect connector C74 from

heater pump.
Disconnect connector C651.B
from VCU.
Remove fuse F15 in order to
take continuity measures from
inside the fuse box.

Refer to the connector

investigation subtree.

Continued on next page

752
Troubleshooting

Continued from previous page

With a multimeter, check for continuity between the

following points:
C74
12V fuse box C14
Connector pin

Pin 3 C5

C74 VCU C651.B

Connector pin Connector pin

Pin 2 Pin 63

Pin 4 Pin 57

C74
Ground
Connector pin

Pin 1 Ground

- Continuity : Resistance is less than or equal to

2ohms.

Yes
Is there any evidence of Defective harness.
continuity loss? Replace harness.

Defective heater pump.

Replace heater pump.

753
Troubleshooting

Complete

B No

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.

Yes

Turn ignition OFF and

Refer to the connector Disconnect connector C74 from
disconnect F15 from 12V fuse
investigation subtree. heater pump.
box C14.

With a multimeter, check for short circuit between

the following points:
C74
Ground
Connector pin

Pin 3 Ground

-LV short: Resistance measurement is less than 100k-

ohms.
-Inspect all connectors and wires between the two
test points of the harness ends.

Continued on next page

754
Troubleshooting

Continued from previous page

Is there any evidence Yes

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 No

Complete
during a test drive?

Yes

Defective heater pump.

Replace heater pump.

755
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.

Relay number Pin A Pin B Pin C Coil Pin A Coil Pin B

K001 4 3 5 1 2
K002 4 3 5 1 2
K003 4 3 5 1 2
K004 87a 30 87 85 86
K005 87a 30 87 85 86
K006 87a 30 87 85 86
K007 87a 30 87 85 86
K008 A1+ A2- X1 X2
K009 4 3 5 1 2
K10 3 5 1 2
K11 3 5 1 2
K012 4 3 5 1 2
K013 4 3 5 1 2
K015 87a 30 87 85 86
K1 T1 T2 X+ X-
T+ T-
K2 T1 T2 X+ X-
T+ T-
K3 T+ T- X+ X-
K4 T+ T- A+ A-
X+ X-

756
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.
Relay Relay
Connector Connector
Pin B Pin C

The multimeter should read a resistance over 1

Mega ohms between these two pins.

Is there any evidence of a Yes

Defective relay.
defect between the pins of
Replace relay.
the relay ?

With an auxiliary 12V power source, apply a 12V voltage

between the following pins :

Relay Relay
Connector Connector
Coil Pin A Coil Pin B

Continued on next page

757
Troubleshooting

Continued from previous page

Is the relay correctly No

closing and opening when Defective relay.
a 12V voltage is applied Replace relay.
and removed ?

Yes

With a multimeter measure the resistance between the

following pins of the relay :

Relay Relay
Connector Connector
Pin B Pin C

The multimeter should read a resistance around 0

ohms between these two pins.
Relay Relay
Connector Connector
Pin B Pin A

The multimeter should read a resistance over 1

Mega ohms between these two pins.

Is there any evidence Yes

Defective relay.
of a defect between the
Replace relay.
pins of the relay ?

Reconnect relay and go back to the

previous troubleshooting tree.

758
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

ESS
Battery TMS CHILL Battery TMS
Chiller tank Chiller_Tank
S-Box SB

Charging system
Charge controller, CCU, PNOVO+ Charge controller, FSVCU, supervisory
FSVCU, Safety controller controller
Charge inlet Inlet
OBC OBC OBC

Propulsion system
Traction inverter MCU Traction inverter
Motor U6 Traction motor

Brake system
Air brake compressor U5 Brake compressor, eCompressor
iAPU U8

HV distribution system
HV junction box JB

DCDC system
DCDC DCDC DCDC

LV distribution system
12V fusebox C14 C14 12V fusebox C14
24V fusebox C20 C20 24V fusebox C20
Equalizer EQ1
LOTO switch LOTO_SW
MPDM MPDM mVEC

Power steering system

EHPS motor EHPS_MTR EHPS motor
EHPS inverter EHPS_INV EHPS inverter

759
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 HTR Cabin Heater
Heater pump HT_PMP HVAC water pump

VCU-HMI system
HMI HMI
VCU VCU Parker MC43

Cooling system
Powertrain coolant pump CLD_PMP

Telemetry system
Telemetry TELEH

ePTO
ePTO EPTO1 ePTO

OEM equipment & misc.

A/C pressure sensor DAF Sensor PN
1320112
Diagnostics DIAGNOSTICS
EBS EBS
External temperature XFD2 EJB
sensor
OB & Shifter PRNDL
DIP DIP
OEM_RADAR OEM_RADAR
VIC VIC

760
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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