Eaton Fuller Hybrid Transmission Fault Code 116 – High Voltage Relays -(MY08 Systems)

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. 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 1 precharge relay on the positive side, an additional relay on the positive, and 1 on the negative for a total of 3. These relays are normally open when the system is off. The relays are controlled through the Inverter.

Fault Code 116 – High Voltage Relays 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 10 is set when the Inverter detects the input voltage measured at the capacitor is less than 210 volts within 3 seconds after the sub-relay closed in the Relay Box.
  • FMI 14 is set when only the negative relay in the Relay Box is on and capacitor voltage decreases less than 10 volts/5 seconds when initial capacitor voltage was greater than 200 volts and motor speed less than 500 min-1, or there is a detect error in the initial check.

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

  • Amber “Check Hybrid” light blinks for FMI 10 and remains solid for FMI 14.
  • Fault is stored in 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 10
    • PEC
    • APG
    • Inverter
    • DC high-voltage cable
    • DC cable interlock loops
    • Inertia Switch
    • Service Switch
  • FMI 14
    • Inverter
    • PEC

Fault Code 116 – High Voltage Relays Test

Component Identification MY08 Systems:

Delphi 56-Way Mating Connector View

56-Way Mating Connector View

High Voltage DC Connector View Yazaki Connector

High Voltage DC Connector View Yazaki Connector

Mating Connector View Deutsch 19 - Way

Mating Connector View Deutsch 19 – Way

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

Inverter PEC connectors Eaton Fuller Hybrid transmission

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.
    Danger: See High-Voltage Service Shutdown and Power-Up Procedures. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.
  3. Which FMIs are present
    • If Fault Code 116 FMI 14 is listed, go to Step 9.
    • If Fault Code 116 FMI 10 is listed, go to Step 2.
    • If no Fault Codes are listed, The Service Switch was pushed in. Go to Step 10.

STEP 2. Verify Data Monitor parameters.

  1. Key on.
  2.  Connect ServiceRanger to the 9-Way Diagnostic Connector in the cab.
  3. Select the “Data Monitor” option.
  4. View the Battery Pack Voltage (BCU1) PID 118 in the high- voltage Battery list:
    • If the Battery Pack Voltage (BCU1) PID 118 is greater than 200 volts, go to Step 3.
    • If the Battery Pack Voltage (BCU1) PID 118 is less than 200 volts, replace the Power Electronics Carrier (PEC), then go to Step 10.

STEP 3. Verify continuity of Inverter connector circuits.

  1. Key off.
  2.  If the vehicle is not equipped with a DC/DC Converter or APG, skip this step.
  3. Using ASTM Class 0 electrical insulating rubber gloves with leather protectors, disconnect the DC cable for the DC/DC Converter and APG at the PEC.
  4. With the key off, temporarily remove the Lockout Bracket and pull the Service Switch out.
  5. Key on.
  6. Is Fault Code 116 FMI 10 still Active in ServiceRanger?
    • If Fault Code 116 FMI 10 is Active with the DC/DC Converter and APG disconnected, go to Step 4.
    • If Fault Code 116 FMI 10 is no longer Active with the DC/DC Converter and APG disconnected, key off and reinstall the Lockout Bracket on the PEC. Replace the Power Electronics Carrier (PEC), then go to Step 10.

STEP 4. Verify continuity of PEC connector circuits to ground.

  1. Key off.
  2. Disconnect the PEC 19-Way Connector.
  3. Temporarily remove the Lockout Bracket and pull the Service Switch out.
    Note: Ensure the Key Switch is off.
  4. Measure resistance at the PEC 19-Way Connector Terminal at the following pins:
    • Pin 17 to Pin 19
    • Pin 9 to Pin 11
    • Pin 13 to Pin 15
      • If the resistance between Pins 17 and Pin 19 is 112–122 ohms and the resistance from Pin 9 to Pin 11 and Pin 13 to Pin 15 are each 33–37 ohms, go to Step 5.
      • If resistance is out of range, go to Step 6.

STEP 5. Verify continuity of Inverter connector circuits to ground.

  1. Key off.
  2. Reconnect the PEC 19-Way Connector.
  3. Disconnect the Inverter 56-Way Connector.
  4. Inspect the connector pins for damaged, corroded and/or loose wires.
  5. Measure resistance between the Inverter 56-Way Connector at the following pins:
    • Pin 29 to Pin 37
    • Pin 30 to Pin 35
    • Pin 31 to Pin 36 Note: Gently flex the Inverter 56-Way Connector Harness near the Connector while monitoring the resistance values.
      • If the resistance between Pin 29 and Pin 37 is 112–122 ohms and the resistance from Pin 30 to Pin 35 and Pin 31 to Pin 36 are each 33–37 ohms, push the Service Switch on the PEC and reinstall the Lockout Bracket. Go to Step 8.
      • If resistance is out of range, repair the Hybrid Harness between the PEC and Inverter, then go to Step 10.

STEP 6. Verify continuity of PEC connector circuits.

  1. Key off.
  2. Remove the Air Filter Cover and Air Filter from the PEC. Refer to TRSM1000 for procedures.*
  3. An Inertia Switch is located at the front of the PEC inside the box and viewable when the Air Filter is removed.
  4. Using ASTM Class 0 electrical insulating rubber gloves with leather protectors, press the button on the top of the Inertia Switch until heard or felt a click. This switch must be depressed a set distance to reset the switch.
  5. Measure resistance at the PEC 19-Way Connector Terminal at the following pins:
    • Pin 17 to Pin 19
    • Pin 9 to Pin 11
    • Pin 13 to Pin 15
      • qIf the resistance between Pin 17 and Pin 19 is 112–122 ohms and the resistance from Pin 9 to Pin 11 and Pin 13 to Pin 15 are each 33–37 ohms, the Inertia Switch was tripped. Test is complete. Go to Step 10.
      • If resistance is out of range, push in the Service Switch on the PEC and reinstall the Lockout Bracket, then go to Step 7.

STEP 7. Verify continuity of Inverter connector circuits.

  1. Key off.
  2. Disconnect the DC High-Voltage Cable at the PEC Bulkhead and at the Inverter Bulkhead.
  3. Measure resistance between the Low-Voltage Interlock Pins on the PEC side of the DC High-Voltage Cable:
    Note: The Interlock Pins are the two small spade terminals located in the same opening.

    • If the resistance is 0–0.3 ohms between the Interlock Loop Pins, replace the Power Electronics Carrier (PEC), then go to Step 10.
    • If resistance is out of range, replace the DC high-voltage cable, then go to Step 10.

STEP 8. Verify continuity of DC Cable from PEC to Inverter Connector circuits.

  1. Key off.
  2. Disconnect the DC High-Voltage Cable at the PEC Bulkhead and the Inverter Bulkhead.
  3. Measure the resistance of each high-voltage circuit on the cable:
    • If the resistance of each high-voltage circuit in the cable is 1 ohm or less, replace the Inverter, then go to Step 10.
    • If resistance is out of range, replace the DC High-Voltage Cable, then go to Step 10.

STEP 9. Verify Data Monitor parameters.

  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.
    • Battery Pack Voltage (BCU1) PID 118
    • Battery Voltage PID 116
      • If the voltage readings on PID 116 and PID 118 are within 10 volts of each other, replace the Power Electronics Carrier (PEC), then go to Step 10.
      • If the voltage readings on PID 116 and PID 118 are greater than 10 volts of each other, replace the Inverter, then go to Step 10.

STEP 10. 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, contact Eaton at 1- 800-826-HELP (4357). Repeat this Step (Step 10).
    • If a code other than 116 appears, see Fault Code Index List.

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