Eaton Fuller Hybrid Transmission Fault Code 107 – High Voltage Battery Leak Detection
Fault code for Eaton Hybrid Drive Systems models (MY08) EH-8E306A-U, EH-8E306A-UPG, EH-8E306A-UP, EH-8E306A-CD, EH-8E306A-T and EH-6E606B-CD. The Battery Control Unit (BCU) continuously monitors the vehicle to detect a high-voltage leak. The circuit is connected to 3 locations on the DC high-voltage line with the opposite end connected to the chassis through a resistor.
Fault Code 107 – High Voltage Battery Leak Detection 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.
- Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Note: When troubleshooting an Inactive code refer to the Product Diagnostic Mode (PDM)
Conditions to Set Fault Code Active
- FMI 1 is set when the BCU detects the resistance between the high-voltage line and the Inverter case is less than 82k ohms.
Fallback When Fault Code 107 is set the following conditions occur:
- Amber “Check Hybrid” light illuminates.
- Fault is stored in Hybrid Control Module (HCM) memory.
- Inverter shuts high-voltage system off.
- HCM continues to control the hybrid vehicle in a diesel-only mode.
- Transmission defaults start gear to 1st.
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 1
- High-voltage cable insulation damage
- High-voltage component leaking
Fault Code 107 – High Voltage Battery Leak Detection Test
Warnings & Cautions
Warning: Warning indicates an immediate hazard, which could result in severe personal injury if you do not follow the indicated procedure.
Caution: Caution indicates vehicle or property damage could occur if you do not follow the indicated procedure.
Note: Note indicates additional detail that will aid in the diagnosis or repair of a component/system.
Follow the specified procedures in the indicated order to avoid personal injury:
1. If the high-voltage cones are around the vehicle and the lockout is installed on the PEC, the only person that should be allowed to start the vehicle is the person who signed the lockout tag.
2. Before working on a vehicle or leaving the cab while the engine is running, you should place the shift lever in “N” set the parking brake, and block the wheels.
3. For safety reasons, always engage the service brakes prior to selecting gear positions from “N.”
4. Before starting a vehicle always be seated in the driver’s seat, select “N” on the shift control, and set the parking brakes.
5. In vehicles with ePTO, the engine and/or
Motor/Generator can start in ePTO mode. Never perform any maintenance or work on vehicle, while in this mode.
6. 12-Volt Battery positive (+) and negative (-) must be disconnected prior to any welding on any Hybrid equipped vehicle.
Caution: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Caution: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
Caution: To avoid damage to the transmission during towing place the shift lever in “N” and lift the drive wheels off the ground or disconnect the driveline.
High-Voltage Warnings & Cautions
- Use CO2 or Dry Chemical Fire Extinguishers.
- The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with warning labels at the connectors.
- All Eaton® Hybrid Diesel/Electric vehicles will be marked ‘Hybrid’ on the outside of the vehicle, along with the shift label on the dash.
- Refer to OEM for specific location of chassis mounted hybrid components.
- Do NOT cut into the orange high-voltage cables.
- Do NOT cut into or open the PEC.
- Do NOT cut into or open the DC/DC Converter.
- Do NOT cut into or open the Inverter.
A buffer zone must be set up and high-voltage insulated rubber gloves (class 0 with leather protectors) are required prior to working on high-voltage. Failure to follow these instructions may result in severe personal injury or death.
The rubber-insulated gloves that must be worn while working on the high-voltage system are class 0 with leather protectors. The rubber gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in “Diagnostic Tools/Service Publications” on page 6. Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 should be followed. Failure to follow these instructions may result in severe personal injury or death.
The Lockout and Tagout devices should only be removed by the technician that placed the Lockout and Tagout devices on the vehicle. Failure to follow these instructions may result in severe personal injury or death.
High-voltage rubber insulated gloves (class 0 with leather protectors) must be worn when working on any
high-voltage cables. The “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 must be followed prior to removing any high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.
High-voltage cables and wiring are orange and contain a warning label at the connectors. High-voltage components are marked with a label. High-voltage rubber insulated gloves (class 0 with leather protectors) must be used when working on any of these components. Failure to follow these instructions may result in severe personal injury or death.
High-Voltage Service Shutdown Procedures
1. Follow “High-Voltage Work Area” procedure.
2. Locate the red PEC Service Switch on the front of the PEC and push switch off.
3. Remove the Service Switch Cover and install the Lockout Bracket (J48506).
4. Fasten tag to the Lockout Bracket.
5. Ensure the PEC Service Switch can not move from the off position.
6. Allow the system to set for a minimum of 5 minutes to discharge high voltage.
7. Connect ServiceRanger and view the Data Monitor PID 116 called “High-Voltage Battery Potential.” Use SPN 520323 for J1939 connection “Battery Voltage RB” (Relay Box).
8. The voltage should be 30 volts or less. If the voltage is above 30 volts, do not work on the vehicle and contact Eaton® at 1-800-826-HELP (4357).
9. Turn ignition key off and proceed to repair or troubleshooting step.
Note: The voltage drops to zero when the key is off.
High-Voltage Service Power-Up Procedure
1. Install all high-voltage connectors into their locked positions.
2. If you are the person working on the vehicle, remove the Lockout Bracket and tag.
3. Reinstall the Lockout Bracket over the Service Switch.
4. Pull the Service Switch out and let vehicle set for 2 minutes.
5. Start vehicle when appropriate.
Eaton Hybrid Component and Connector Location
Eaton Hybrid Component and Connector Location MY09 Systems
STEP 1.Verify Active and Inactive fault code status.
- Review and follow the Warnings & Cautions.
- Key on.
- Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector or manually.
- If Fault Code 107 is Active go to Step 2.
- If Fault Code 107 in Inactive, test is complete. Go to Step 16.
STEP 2. Verify continuity of PEC DC Cable connector terminals and shielding.
- Key off.
- Disconnect the Inverter DC Connector at the PEC.
Warning: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - Measure the resistance to ground at the DC Cable Connector on both the positive and negative terminals.
- If Open or “OL” on meter, go to Step 9.
- If any resistance/continuity is found, go to Step 3.
STEP 3. Verify continuity of Inverter DC Cable connector terminals and shielding.
- Disconnect the DC Connector at the Inverter.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - With the DC Cable disconnected at both ends measure the resistance to cable shielding at both the positive and negative terminals.
- If Open or “OL” on meter, go to Step 4.
- If any resistance/continuity is found, replace DC High-Voltage Cable between the PEC and Inverter, then go to Step 16.
STEP 4. Verify continuity of Inverter DC connector.
- Measure the resistance to ground at the Inverter DC Connector on both positive and negative terminals:
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.- If Open or “OL” on meter, possible error with testing. Go to Step 16.
- If any resistance/continuity is found, go to Step 5.
STEP 5. Verify continuity of Inverter AC Cable.
- Disconnect the DC Connector at the Inverter.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - Measure the resistance to ground on all three terminals at the AC Cable.
- If Open or “OL” on meter, go to Step 6.
- If any resistance/continuity is found, go to Step 7.
STEP 6. Verify continuity of Inverter AC Cable to ground.
- Measure the resistance to ground at all 3 terminals at the Inverter AC Connector.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.- If Open or “OL” on meter, possible error with testing. Go to Step 16.
- If any resistance/continuity is found, replace inverter, then go to Step 16.
STEP 7. Verify continuity of AC High-Voltage Cable terminals and shielding.
- Disconnect the AC High-Voltage 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. - With the AC Cable disconnected at both ends, measure resistance to cable shielding at all 3 terminals.
- If Open or “OL” on meter, go to Step 8.
- If any resistance/continuity is found, replace AC high-voltage cable, then go to Step 16.
STEP 8. Verify continuity of Motor/Generator AC Connector to ground.
- Measure the resistance to ground at the Motor/Generator AC Connector.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.- If Open or “OL” on meter, possible error with testing. Go to Step 16.
- If any resistance/continuity is found, replace motor/generator, then go to Step 16.
STEP 9. Verify components present.
- Is unit supplied with a DC/DC Converter or APG?
- Yes, go to Step 10.
- No, replace Power Electronics Carrier (PEC), then go to Step 16.
STEP 10. Verify continuity of DC cable from PEC to DC/DC Converter.
- Disconnect 12-volt positive and negative cables from DC/DC Converter.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - Disconnect the PEC to DC/DC Converter DC Cable at the PEC.
- Measure the resistance to ground at the DC Cable connector on both the positive and negative terminals.
- If Open or “OL” on meter, possible error in testing. If vehicle does not have an APG, go to Step 16.
- If vehicle is equipped with APG, go to Step 13.
- If any resistance/continuity is found, go to Step 11.
STEP 11. Verify continuity of PEC High-Voltage DC Cable terminals to shielding.
- Disconnect the high-voltage DC cable at the DC/DC Converter.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - With the DC cable disconnected at both ends, measure resistance to cable shielding at positive and negative terminals.
- If Open or “OL” on meter, go to Step 12.
- If any resistance/continuity is found, replace the High-Voltage DC Cable, then go to Step 16.
STEP 12. Verify continuity of DC/DC Converter DC high-voltage cable terminals to ground.
- Measure the resistance to ground at the DC/DC Converter High-Voltage DC Connector at both positive and negative terminals.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.- If Open or “OL” on meter, possible error with testing. Go to Step 16.
- If any resistance/continuity is found, replace DC/DC Converter, then go to Step 16.
STEP 13. Verify continuity of APG DC high-voltage cable terminals to ground.
- Disconnect the APG DC High-Voltage Cable at the PEC.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - Measure the resistance to ground at the DC Cable Connector on both the positive and negative terminals.
- If Open or “OL” on meter, replace the Power Electronics Carrier (PEC), then go to Step 16.
- If any resistance/continuity is found, go to Step 14.
STEP 14. Verify continuity of APG DC high-voltage cable terminals to shielding.
- 1. Disconnect the high-voltage DC cable at the APG.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - With the DC cable disconnected at both ends measure the resistance from positive and negative terminals to cable shielding at PEC Cable end.
- If Open or “OL” on meter, go to Step 15.
- If any resistance/continuity is found, replace DC high-voltage cable, then go to Step 16.
STEP 15. Verify continuity of APG high-voltage DC cable pin to ground.
- Measure the resistance to ground at APG High-Voltage DC connector Pin 1 (positive +) and Pin 4 (negative -).
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.- If Open or “OL” on meter, possible error with testing. Go to Step 16.
- If any resistance/continuity is found, replace Auxiliary Power Generator (APG) Inverter, then go to Step 16.
STEP 16. Verify repair.
- Key off.
- Reconnect all connectors.
Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage. - Key on.
- Drive the vehicle and attempt to reset the code.
- Check for codes, see View Active and Inactive Faults.
- If no codes, test is complete.
- If fault Code 107 appears, find error in testing, go to Step 1.
- If a code other than 107 appears, see Fault Code Index List.
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