Eaton Fuller Hybrid Fault Code 16 – High Integrity Link (HIL) Test

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 High Integrity Link (HIL) is a high-speed twisted pair 500K proprietary data link that connects the Transmission Electronic Control Unit (TECU) to the Push Button Shift Control (PBSC). Each module contains an internal 120-ohm resistor. The HIL carries information such as driver mode selection and fault information to illuminate the
“Service” light.

Fault Code 16 – High Integrity Link (HIL) Detection

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

  • TECU ignition voltage is greater than 7 volts and less than 16 volts.
  •  TECU System Battery Voltage Low Fault is Inactive.
  • TECU driver interface configuration is set to HIL.

Conditions to Set Fault Code Active

Conditions to Set Fault:
• FMI 2 is set when the TECU loses communication for 5 seconds or more with the PBSC.

Fallback When Fault Code 16 is set the following conditions occur:

  •  An “F” appears in the gear display.
  • Push Button Mode Light flashes next to the selected mode and the “Service” light remains off.
  • Push Button lights come on and then remains off if the data link fails at power up.
  • Fault is stored in TECU memory.
  • Operation mode changes to AutoShift Fallback mode.
  • If the code is Active during power up, transmission does not engage a gear.
  •  If the fault is Active while driving, transmission remains in the current gear. It then shifts into the default gear once the vehicle stops. Clutch opens at idle and closes if the throttle is pressed. The vehicle moves into the default start gear only.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The TECU automatically clears faults from history after 200 hours. The HCM automatically clears faults from history after that fault has been Inactive for 200 hours.

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

  • FMI 2
    • HIL Data Link
    • PBSC
    • TECU
    • Power Supply Harness from TECU to PBSC

Fault Code 16 – High Integrity Link (HIL) Test

Component Identification:

Fuller Harness Front View TECU - Vehicle Interface Connector

Fuller Harness Front View
TECU – Vehicle Interface Connector

Eaton Harness Front View Push Button Shift Control Connector

Harness Front View
Push Button Shift Control Connector

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

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

Eaton Fuller transmission TECU PBSC connection

STEP 1. Check for Active or Inactive fault code status.

  1. Review and follow the Warnings & Cautions.
  2.  Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.
  3. 3. Key on and observe the red Push Button “Service” light.
    • If the red “Service” light turns on, go to Step 3.
    • If the red “Service” light does not turn on, go to Step 2.

Step 2. Verify voltages at Vehicle Harness.

  1. Disconnect Shift Control 30-Way Connector.
  2. Key on.
  3. Measure voltage on 30-Way Connector between Pin J3 and Pin C1.
    • If voltage is within 0.6 volts of battery voltage, go to Step 3.
    • If out of range, go to Step 4.

Step 3. Verify voltage at Push Button Shift Controller.

        1. Key off
        2. Disconnect the 30-Way Push Button Shift Control Connector.
        3. Key on.
        4. Connect voltmeter leads to Pin F1 and Pin F2.
          Note* Make sure the volt/ohm meter is on the proper scale; around 10 volts AC.

          • If the voltage is 0.10 volts AC or greater, replace the Shift Control (only if fault code is active), then go to step 8.
          • If the voltage is out of range, go to step 6.

STEP 4. Verify continuity from Vehicle Harness to Push Button Shift Controller.

    1. Key off
    2. Disconnect negative battery cable.
    3. Disconnect Vehicle Harness 38-Way Connector 
      Note:       On Peterbilts, disconnect gear display
    4. Measure resistance between:
      • Shift Control 30-Way Connector Pin J3 and Vehicle Harness 38-Way Connector Pin 25.
        • If resistance between Pin J3 and Pin 25 is 0–0.3 ohms, go to Step 5.
        • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU, then go to Step 8.

STEP 5. Verify continuity from Push Button Shift Controller circuits to ground.

    1. Key off
    2. Measure the resistance between:
      • Shift Control 30-Way Connector Pin C1 and Vehicle Harness 38-Way Connector Pin 31.
      • Shift Control 30-Way Connector Pin C1 and ground.
    3. If resistance between Pin C1 and Pin 31 is 0–0.3 ohms and resistance between Pin C1 and ground is 10K ohms or greater, replace Transmission  Electronic Control Unit (TECU)(Only if Fault Code is Active).
    4. If any of the above conditions are not met, repair the Vehicle Harness between the TECU and Shift Control, then go to Step 8.

Step 6. Verify continuity from Push Button Shift Controller circuits to ground.

        1. Key off.
        2. Disconnect negative battery cable.
        3. Disconnect Vehicle Harness 38-Way Connector.
        4. Measure resistance between:
          • Shift Control 30-Way Connector Pin F1 and Vehicle Harness 38-Way Connector Pin 28
          • Shift Control 30-Way Connector Pin F1 and ground.
        5. If resistance between Pin F1 and Pin 28 is 0–0.3 ohms and if resistance between Pin F1 and ground is 10K ohms or greater, go to Step 7.
        6. If any of the above conditions are not met, repair Vehicle Harness between the Shift Control and TECU, then go to Step 8.

Step 7. Verify continuity from Vehicle Harness to Push Button Shift Controller.

    1. Key off
    2. Measure resistance between:
      • Shift Control 30-Way Connector Pin F2 and Vehicle Harness 38-Way Connector Pin 27.
      • Shift Control 30-Way Connector Pin F2 and ground.
    3.  If resistance between Pin F2 and Pin 27 is 0–0.3 ohms and resistance between Pin F2 and ground is 10K ohms or greater, replace Transmission Electronic Control Unit (TECU)(Only if Fault Code is Active). Go to Step 8.
    4. If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU, then go to Step 8.

STEP 8. Verify repair.

  1. Key off.
  2.  Reconnect all connectors and negative battery cable.
  3. Key on.
  4. Clear codes, see  Clear Inactive Faults.
  5. Drive the vehicle and attempt to reset the code.
  6. Check for codes, see View Active and Inactive Faults.
    • If no codes, test is complete.
    • If fault Code 16 appears, find error in testing, go to Step 1.
    • If a code other than 16 appears, see Fault Code Index List.

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