Eaton Fuller Hybrid Fault Code 2 Motor / Generator Temperature Sensor

Fault code for Eaton Hybrid Drive Systems models (MY08) EH-8E306A-U, EH-8E306A-UPG, EH-8E306A-UP, EH-8E306A-CD, EH-8E306A-T, EH-6E606B-CD, (MY09) EH-8E406A-U/P, EH-8E406A-UP, EH-8E406A-UPG, EH-8E406A-CD, EH-8E406A-CDG, EH-8E406A-CDR, EH-8E406A-T, EH-6E706B-CD, EH-6E706B-P and EH-6E706B-UPG. The Motor/Generator Temperature Sensor is a thermistor located inside the Motor/Generator that changes in value based on the temperature. The Inverter supplies a 5-volt reference voltage to the sensor and measures the volt drop in the circuit. When the Motor/Generator temperature is warm, the sensor resistance is low and the Inverter detects low-voltage (0.2 volts equals 536 °F [280 °C]). When the Motor/Generator is cold the sensor resistance is high and the Inverter detects high voltage (4.1 volts equals or 32 °F [0 °C]).

Fault Code 2 – Motor / Generator Temperature Sensor Detection

The following preconditions must be met before the system detects the fault:

  • Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

Conditions to Set Fault:
• FMI 3 is set when the sensor voltage is greater than 4.1 volts for 10 seconds, while the Inverter temperature is over 35 °C or 95 °F, or if the sensor output voltage is less than 0.2 volts for 10 seconds.

Fallback When Fault Code 2 is set the following conditions occur:
• Amber “Check Hybrid” light illuminates.
• Fault is stored in Hybrid Control Module (HCM) memory.
• High-Voltage Motor/Generator Assist is available, but at a reduced amount.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours and the HCM automatically clears the faults from history after the fault has been Inactive for 200 hours.

This fault code can be caused by any of the following:

  • FMI 3
    • Motor/Generator
    • Short/open Temperature Sensor wires between the Motor/Generator and the Inverter
    • Inverter

Fault Code 2 – Motor/Generator Temperature Sensor Test

Component Identification MY08 Series:

Delphi 56-Way Mating Connector View

Delphi 56-Way Mating Connector View

Temperature Sensor

Temperature Sensor
(Harness View – Front Side)

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

Eaton Fuller inverter connection

Component Identification MY09 Series:

Deutsch 40-Way Mating Connector View

Deutsch 40-Way Mating Connector View
(Inverter – Low Voltage Connector)

Terminal Side - Harness Connector Temperature Sensor

Terminal Side – Harness Connector Temperature Sensor
(Deutsch 2-pin connector)

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

Eaton Fuller inverter connection MY09

STEP 1. Check for fault code status and continuity of Motor/Generator Temperature Sensor circuit

  1. Review and follow the Warnings & Cautions.
  2.  Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.
  3. Key off.
  4. Disconnect the Temperature Sensor Connector at the Motor/Generator.
    Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.
  5. Measure resistance at the Motor/Generator 2-Way Temperature Sensor Connector from Pin A to Pin B(MY08)/ Pin 1 to Pin 2(MY09):
    • If resistance is 0.8K ohms to 301.7K ohms, go to Step 2.
    • If resistance is outside of range, replace the Motor/Generator, then go to Step 3.

STEP 2. Verify continuity of Inverter and Motor/Generator Temperature Sensor circuit.

  1. Key off
  2. Disconnect the Inverter 56-Way Connector.
  3. Reconnect the Motor/Generator 2-Way Temperature Sensor Connector.
  4. Measure resistance at the following:
      • Inverter 56-Way Connector Pin 50 to Pin 38(MY08) / 40-Way Connector Pin 37 to Pin 36, Inverter(MY09.
      • Inverter 56-Way Connector Pin 50 to ground (MY08) / 40-Way Connector Pin 37 to ground (MY09).

    Note: Gently flex the Inverter 56-Way Harness near the Connector while monitoring the resistance values.

    1. If resistance is 0.8K–301.7K ohms between Pin 50 and Pin 38 (37 & 37) and resistance between Pin 50 (37) and ground is 10K ohms or greater, replace the Inverter, then go to Step 3.
    2. If resistance is outside of range, repair the open or short to ground in the harness between the Inverter Connector and the Motor/Generator 2-Way Connector, then go to Step 3.

STEP 3. Verify repair.

  1. Key off.
  2.  Reconnect all connectors and the negative battery cable.
  3.  Key on.
  4. Clear codes.
  5. Drive vehicle and attempt to reset the code.
  6. Check for codes.
    •  If no codes, test is complete.
    • If Fault Code 2 appears, find error in testing, go to Step 1.
    • If a code other than 2 appears, see Fault Code Index List.

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