Eaton Fuller Hybrid Transmission Fault Code 116 – High Voltage Relays Fault – (MY09 systems)

Fault code for Eaton Hybrid Drive Systems models (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. Read below to learn how to test, clear and fix fault code errors for your Freightliner, Mack, Peterbilt, Kenworth, Volvo, International, and heavy-duty truck and equipment. The High-Voltage Relays are located inside the Power
Electronics Carrier (PEC) in the Relay Box unit. There is one Pre-Charge Relay on the positive side, an additional relay on the positive, and on the negative for a total of three relays. These relays are normally open when the system is off. The relays are controlled through the Inverter.

Fault Code 116 – High Voltage Relays Fault 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.

Note: When troubleshooting an Inactive code refer to the Product Diagnostic Mode (PDM)

Conditions to Set Fault Code Active

  • FMI 3 is set when a short to 12 volts is detected on the control side of a high-voltage relay.
  • FMI 4 is set when a short to ground is detected on the control side of a high-voltage relay.
  • FMI 5 and FMI 10 are set when an open circuit is detected on the control side of a high-voltage relay.
  • FMI 7 and FMI 14 are set when the main negative relay is on and the inverter capacitor voltage decrease is less than 10-volts / 5 seconds when initial capacitor voltage was greater than 200 volts.

Fallback When Fault Code 116 is set the following conditions occur:

  • Amber “Check Hybrid” light illuminates.
  • Fault is stored in Hybrid Control Module (HCM) memory.
  • The hybrid system will be offline.
  • Transmission defaults start gear to 1st in diesel-only mode.

Conditions to Set Fault Code Inactive

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

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

  • FMI 3, 4, 5, 7, 10, 14
    • Voltage Feedback wire from DC/DC Converter to HCM
  • FMI 4
    • Relay Box
    • Inertia Switch
    • Inverter
    • Vehicle Wiring Harness between the Inverter and the PEC
    • Main High-Voltage Service Fuse is blown or missing
    • DC High-Voltage Cable Interlock
    • PEC Red Button Service Switch

Fault Code 116 – High Voltage Relays Fault Test

Component Identification:

Duetsch 40-way mating connector view Inverter low-voltage connector

Duetsch 40-way mating connector view
(Inverter low-voltage connector)

Mating connector view Deutsch 19-way

Mating connector view
(Deutsch 19-way connector)

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

Inverter to PEC MY09 Systems

STEP 1.Verify FMIs present.

  1. Review and follow the Warnings & Cautions.
  2.  Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.
  3. Using ServiceRanger, record readings in “Data Monitor” under J1939 Data HV Battery: Parameter 520250 HV Battery1 potential voltage and parameter 520323 Battery Voltage RB. Watch voltage on Battery Voltage RB during key on and record voltage steps if any are present.
  4.  Which FMIs are present?
    • If Fault Code 116 FMI 3 is listed, go to Step 2.
    • If Fault Code 116 FMI 4 is listed, go to Step 4.
    • If Fault Code 116 FMI 5 or 10 is listed, go to Step 6.
    • If Fault Code 116 FMI 7 is listed, go to Step 13.

STEP 2. Verify repair.

  1. Key off, wait 1 minute.
  2. Disconnect the 40-Way Inverter Connector.
  3. Key on (this will set a Fault Code 88, clear fault after repairing).
  4. On Vehicle Harness, check for any voltage on pins 21, 31, 22, 32, 23 and 33 to ground:
    • If any voltage is found, remove 19-Way Connector on the PEC and recheck for voltage at Inverter 40-Pin, then go to Step 3.
    • If voltage is still present, repair Vehicle between Inverter and the 40-Pin, then go to Step 3.
    • If voltage is gone, go to Step 3

STEP 3. Verify continuity of PEC Connector circuits to ground.

  1. 1. Key off.
    2. Disconnect the PEC 19-Way Connector (red Service Switch should still be pulled out).
    3. Measure the resistance on the following 19-Way Connector terminals:

    • Pin 9 to Pin 6 and Pin 9 to Pin 12
    • Pin 13 to Pin 6 and Pin 13 to Pin 12
    • Pin 17 to Pin 6 and Pin 17 to Pin 12
      • If open circuit, go to Step 2.
      • If any resistance is found, replace the Relay Box, then go to Step 14.

STEP 4. Verify continuity of Inverter Connector circuits.

  1. Key off.
  2. Disconnect the Inverter 40-Way Connector (19-Way Connector at PEC should be connected with red Service Switch pulled out).
  3. On Vehicle Harness, check for resistance to ground on Pin 21 to ground, Pin 22 to ground and Pin 23 to ground:
    • If any resistance from the Inverter Connectors to ground is found, disconnect PEC 19-Way Connector and recheck the OEM 40-Way Connector.
    • If resistance is still found with the 19-Way disconnected, repair the Vehicle Harness, then go to Step 14.
    • If resistance is gone with the 19-Way disconnected, go to Step 5.
    • If meter reads OL or Open Circuit, replace the Inverter, then go to Step 14.

STEP 5. Verify continuity of PEC Connector circuits to ground.

  1. Key off.
  2. Disconnect the PEC 19-Way Connector.
  3. On the PEC 19-Way Connector, measure:
    • Pin 9, Pin 13 and Pin 17 to ground
    • Pin 9 to Pin 7, Pin 9 to Pin 10, Pin 9 to PEC Mounting Stud
    • Pin 13 to Pin 7, Pin 13 to Pin 14, Pin 13 to PEC Mounting Stud
    • Pin 17 to Pin 7, Pin 17 to Pin 14, Pin 17 to PEC Mounting Stud
      • If any resistance is found from the PEC Pins to ground, replace the Relay Box. See the MY09 PEC High-Voltage Relay Box Removal and Installation procedure in TRSM2000, then go to Step 14.
      • If meter reads OL, retesting is required, go to Step 4.

STEP 6. Verify continuity of PEC Connector circuits.

  1. Key off.
  2. Disconnect the PEC 19-Way Connector. (Red Service Button on PEC should be pulled out.)(Do not perform “Hybrid Shutdown Procedure” yet.)
  3. Measure resistance on the PEC Connector:
    • Pin 9 to Pin 11
    • Pin 13 to Pin 15
    • Pin 17 to Pin 19
      • If the resistance between Pin 9 and Pin 11, and Pin 13 to Pin 15 are each 33–37 ohms and the resistance from Pin 17 to Pin 19 is 112–122 ohms, go to Step 7.
      • If any resistance is outside of range, reset the Inertia Switch located inside air filter opening or in Rear Access Panel by the High-Voltage Fuse, then go to Step 14.

STEP 7. Check the high-voltage cable Interlock on the OEM Cable.

  1. Verify that the Inertia Switch is OK.
  2. Measure resistance of the Interlock Pins on the OEM Cable.
    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 resistance is 0–0.3 ohms, replace the Relay Box, then go to Step 9.
    • If resistance is OL, replace the High-Voltage DC Cable, then go to Step 8.

STEP 8. Verify continuity of PEC Connector circuits to ground.

  1. Measure resistance on the PEC Connector (red Service Button Switch is pulled out):
    • Pin 9 to Pin 11
    • Pin 17 to Pin 19
      • If any resistance is OL, replace the Relay Box (inspect wiring going into Relay Box before replacing), then go to Step 9.

STEP 9.

  1. Key off.
  2. If vehicle is equipped with Export Power PEC, perform “High-Voltage Service Shutdown and Power-Up Procedure” on page 4, then remove High-Voltage DC/DC and/or APG High-Voltage Cable from the PEC. Install Interlock Caps if available:
    • If vehicle is NOT equipped with Export Power, go to Step 11.

STEP 10.

  1. After DC/DC and APG high-voltage cables are removed, pull out red Service Switch and connect 19- Way Connector at the PEC.
  2. Key on:
    • If Fault Code 116/FMI 5 is still Active, go to Step 12.
    • If Fault Code 116/FMI 5 is gone, go to Step 14.

STEP 11.

  1. Key off.
  2. Plug DC/DC and/or APG cables back into PEC and verify that Fault Code 116/FMI 5 is still Active:
    • If still Active, go to Step 12.
    • If Inactive, the Auxiliary Relays inside the PEC are welded. Replace the PEC. See the MY09 Power Electric Carrier (PEC) Removal and Installation, Alternative Power Electric Carrier (PEC) Removal and Installation or 4- Battery Power Electric Carrier (PEC) Removal and Installation procedures in TRSM2000.
      Also, inspect the Auxiliary Relay Circuit for loose Interlock Connections causing relay chatter under load see Fault Code 118 – Auxiliary High Voltage Relay Control Circuit Fault for circuit description).
    • After repairs are completed, go to Step 14.

STEP 12. Verify continuity of Inverter Connector circuits.

  1. Connect the PEC 19-Way Connector.
  2. Disconnect the Inverter 40-Way Connector.
  3. Measure resistance at the Inverter 40-Way OEM Connector Terminal at the following pins:
    • Pin 21 to Pin 31
    • Pin 22 to Pin 32
    • Pin 23 to Pin 33
      • If the resistance between Pin 21 and Pin 31 is 112–122 ohms and the resistance from Pin 22 to Pin 32, and Pin 23 to Pin 33 are each 33–37 ohms, replace the Inverter (see MY09 Inverter Removal and Installation), then go to Step 14.
      • If resistance is out of range, repair the Vehicle Harness between the Inverter and the PEC, then go to Step 14.

STEP 13. Measure battery voltage.

  1. Connect ServiceRanger to the 9-Way Diagnostic Connector in the cab.
  2. Select the “Data Monitor” option.
  3. View the following parameters in the high-voltage battery list:
    • HV Battery J1939 Data HV Battery:
      Parameter 520250 HV Battery1 Potential Voltage and Parameter 520323 Battery Voltage RB
    • Push in the red Service Button.
    • If the voltage readings on Battery1 Potential Voltage and Battery Voltage RB are within 10 volts of each other (Battery Voltage RB should drop to 30 volts when the red Service Switch was pushed in), replace the Relay Box. See the MY09 PEC High-Voltage Relay Box Removal and Installation procedure in TRSM2000, then go to Step 14.
      Note: “High-Voltage Service Shutdown and
      See High-Voltage Service Shutdown and Power-Up Procedures must be performed before removing high-voltage cable. (If main
      High-Voltage Relays are welded, remove high-voltage fuse located in Rear Access Panel before attempting any repairs).
    • If the voltage readings on Battery1 Potential Voltage and Battery Voltage RB are greater than 10 volts of each other (Battery Voltage RB should drop to 30 volts when the red Service Switch was pushed in), replace the Inverter, then go to Step 14.

STEP 14. Verify repair.

  1. Key off.
  2. Reconnect all connectors and the 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 116 appears, find error in testing, go to Step 1.
    • If a code other than 116 appears, see Fault Code Index List.

Any transmission part you need we have it! Same day shipping available, worldwide.

NEED FREE SUPPORT FROM ONE OF OUR EXPERTS?

CALL NOW
EMAIL US