Trts0930 Eaton Gen 3 Autoshift Ultrashift Troubleshooting Guide
User Manual: Eaton-Gen-3-Autoshift-Ultrashift--Troubleshooting-Guide Freightliner
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Troubleshooting Guide Eaton Gen III Automated Transmissions TRTS0930 EN-US January 2016 UltraShift® AutoShift® Model: F-5405B-DM3 F-6405B-DM3 FM-14D310B-LST FM-15D310B-LST FO-16D313E-LEP FO-5406B-DM3 FO-6406A-AW3 FO-6406B-AW3 FO-8406A-AW3 FOM-16D313E-LEP RTLO-14918A-AS3 RTLO-16913L-DM3 RTLO-16918A-AS3 RTO-10910B-DM3 RTO-12910B-AS3 RTO-12910B-DM3 RTO-14910B-AS3 RTO-14910B-DM3 RTO-14910C-AS3 RTO-16910B-AS3 RTO-16910B-DM3 RTO-16910C-AS3 RTO-18910B-AS3 F-5505B-DM3 F-6505B-DM3 RTLO-18918A-AS3 RTLO-20918A-AS3 RTLO-22918A-AS3 RTLOM-16913L-DM3 RTO-10910B-AS3 RTOM-16910B-DM3 TRTS0930 Table of Contents Table of Contents General Information Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . .1 Transmission Models . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fault Code Retrieval/Clearing . . . . . . . . . . . . . . . . . . . . .5 Retrieving Fault Codes Manually. . . . . . . . . . . . . . . 5 Clearing Fault Codes Manually . . . . . . . . . . . . . . . . 6 Retrieving Fault Codes with ServiceRanger . . . . . . 6 Clearing Fault Codes with ServiceRanger . . . . . . . . 7 Fault Code Isolation Procedure Index. . . . . . . . . . . . . . .8 Symptom-Driven Diagnostics Index. . . . . . . . . . . . . . .10 Product Diagnostic (PD) Mode . . . . . . . . . . . . . . . . . .11 Pretest Procedures Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 TECU Power Harness . . . . . . . . . . . . . . . . . . . . . . 13 Preferred +12 Volt Connections . . . . . . . . . . . . . . 14 Preferred +12 Volt Connections . . . . . . . . . . . . . . 15 Preferred +24 Volt Connections . . . . . . . . . . . . . . 16 Preferred +24 Volt Connections . . . . . . . . . . . . . . 17 TECU Ignition Circuit . . . . . . . . . . . . . . . . . . . . . . 18 J1939 Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . 19 J1939 Troubleshooting. . . . . . . . . . . . . . . . . . . . . 19 Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Power-Up Sequence Test . . . . . . . . . . . . . . . . . . . . . . .22 Fault Isolation Procedures Fault Code 11 - No TECU Operation . . . . . . . . . . . . . . .30 Fault Code 12 - Improper ECU Configuration . . . . . . . .34 Fault Code 13 - J1939 Shift Control Device . . . . . . . . .38 Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Fault Code 14 - Invalid Shift Lever Voltage (with Park Pawl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Fault Code 15 - HIL Shift Device Configuration . . . . . .54 Fault Code 16 - High Integrity Link (HIL) . . . . . . . . . . .62 Fault Code 17 - Start Enable Relay (SER) Circuit . . . . .70 Fault Code 21 - Auto Neutral Park Brake Switch. . . . . .74 Fault Code 22 - ABS CAN Message Fault . . . . . . . . . . .80 Fault Code 26 - Clutch Slip . . . . . . . . . . . . . . . . . . . . . .84 Fault Code 27 - Clutch Disengagement . . . . . . . . . . . .88 Fault Code 28 - Clutch System . . . . . . . . . . . . . . . . . . .92 Fault Code 29 - Remote Throttle Enable . . . . . . . . . . . .98 2016.01.15 Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Fault Code 32 - Loss of Switch Ignition Power Test. .108 Fault Code 33 - Low Battery Voltage Supply . . . . . . .112 Fault Code 34 - Weak Battery Voltage Supply . . . . . .118 Fault Code 35 - J1939 Communication Link. . . . . . . .124 Fault Code 36 - J1939 Engine Message . . . . . . . . . . .130 Fault Code 37 - Power Supply . . . . . . . . . . . . . . . . . .136 Fault Code 41 - Range Failed to Engage . . . . . . . . . . .142 Fault Code 42 - Splitter Failed to Engage . . . . . . . . . .148 Fault Code 43 - Range Solenoid Valve . . . . . . . . . . . .154 Fault Code 44 - Inertia Brake Solenoid Coil . . . . . . . .160 Fault Code 45 - High Capacity (HCIB) Failure . . . . . . .166 Fault Code 46 - Splitter Direct and Indirect Solenoid Valve 170 Fault Code 51 - Rail Position Sensor . . . . . . . . . . . . .176 Fault Code 52 - Gear Position Sensor. . . . . . . . . . . . .182 Fault Code 56 - Input Shaft Speed Sensor . . . . . . . . .188 Fault Code 57 - Main Shaft Speed Sensor . . . . . . . . .194 Fault Code 58 - Output Shaft Speed Sensor . . . . . . . .198 Fault Code 61 - Rail Select Motor. . . . . . . . . . . . . . . .202 Fault Code 63 - Gear Select Motor . . . . . . . . . . . . . . .208 Fault Code 68 - Grade Sensor . . . . . . . . . . . . . . . . . .214 Fault Code 71 - Unable to Disengage Gear . . . . . . . . .218 Fault Code 72 - Failed to Select Rail . . . . . . . . . . . . . .224 Fault Code 73 - Failed to Engage Gear . . . . . . . . . . . .230 Fault Code 74 - Engine Speed Response Fault . . . . . .236 Fault Code 75 - Power Down In Gear . . . . . . . . . . . . .240 Fault Code 81 - Gear Engagement Detected . . . . . . . .244 Fault Code 83 - Shift Lever Missing . . . . . . . . . . . . . .248 Fault Code 84 - Shift Control Device Not Configured .252 Fault Code 85 - Shift Control Device Incompatible . . .256 Fault Code 99 - Direction Mismatch . . . . . . . . . . . . . .260 © 2016 Eaton. All rights reserved i TRTS0930 Table of Contents Symptom Isolation Procedures Up/Down Button Test. . . . . . . . . . . . . . . . . . . . . . . . . 264 Start Enable Relay Contact Test . . . . . . . . . . . . . . . . . 268 J1587 Data Link Test . . . . . . . . . . . . . . . . . . . . . . . . . 276 Front Box Control Test . . . . . . . . . . . . . . . . . . . . . . . . 282 AutoShift Will Not Engage a Gear from Neutral Test . 288 UltraShift DM3 Will Not Engage a Gear from Neutral Test 296 UltraShift AW3 Clutch Engagement Test . . . . . . . . . . 302 AutoShift AS3 Shift Complaint Test . . . . . . . . . . . . . . 306 UltraShift DM3 Shift Complaint Test . . . . . . . . . . . . . 316 UltraShift AW3 Shift Complaint Test . . . . . . . . . . . . . 326 Shift Lever Back Light Test . . . . . . . . . . . . . . . . . . . . 334 OEM Shift Lever Wiring Diagram . . . . . . . . . . . . 368 Eaton Push Button Wiring Diagram . . . . . . . . . . 369 OEM J1939 Shift Input Device Wiring Diagram . 371 Proper Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 372 Check For Proper Clutch Operation . . . . . . . . . . 372 Confirm Proper Clutch Adjustment and Clutch Brake Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Clutch Grease Interval Service Procedure . . . . . 374 Adapter Test Kit J43318 . . . . . . . . . . . . . . . . . . . . . . 375 Appendix Connector Pin Descriptions . . . . . . . . . . . . . . . . . . . . 340 Transmission Controller 38-Way (Vehicle Interface Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Push Button Shift Control 30-Way Connector . . 341 Cobra Lever 8-Way Connector . . . . . . . . . . . . . . 341 Transmission Controller 38-Way (Eaton Supplied Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 UltraShift DM3 6-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 UltraShift DM3 6-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 345 UltraShift AW3 6-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 UltraShift AW3 6-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 349 AutoShift 10-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 AutoShift 10-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 353 UltraShift 10-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 UltraShift 10-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 357 UltraShift 13-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 UltraShift 13-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 361 AutoShift 18-Speed Wiring Diagram with Analog Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 AutoShift 18-Speed Wiring Diagram with Push Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Eaton Cobra Lever Wiring Diagram . . . . . . . . . . 367 ii © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Warnings and Cautions Warnings and Cautions ! Warning: Follow the specified procedures in the indicated order to avoid personal injury ! Caution: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage. Note: Additional relevant information not covered in the service procedure. Ensure adequate fuel level • Sit in the driver's seat • Place shift lever in neutral • Set the parking brake ! • Place shift lever in neutral • Set the parking brake Caution: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level. To avoid damage to the transmission during towing: Before starting a vehicle: • When parking the vehicle or leaving the cab: 1. Place shift lever in neutral 2. Lift the drive wheels off of the ground or disconnect the driveline Do not operate the vehicle if Alternator light is lit or if gauges indicate low voltage. Before working on a vehicle or leaving the cab with engine running: • Ensure ignition is off while hands are within the clutch housing area. • Place shift lever in neutral • Set the parking brake • Block the wheels 2016.01.15 © 2016 Eaton. All rights reserved 1 TRTS0930 Transmission Models | General Information Transmission Models 2 Heavy-Duty 13-Speed DM3/LEP and 18-Speed AS3 Heavy-Duty 10-Speed AS3/DM3 Medium-Duty 6- and 5-Speed DM3 Medium-Duty 6-Speed AW3 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Diagnostic Procedures Diagnostic Procedures A Purpose: Observe the transmission gear display. 1. Key on. B Purpose: Confirm that the engine will crank and start. 1. Attempt to start engine 2. Observe gear display. Note: An “88” may show up in the dash at key on. This indicates the Transmission Electronic Control Unit (TECU) has completed power-up. If the transmission and gear display power-up at the same time, you may not see an “88”. • If blank gear display, go to Step B. • If “-” (1 dash) on gear display, go to Step D. • If “--” (2 dashes) or “**” (2 stars) on gear display, go to Step D. • “#” (gear number) on gear display - Verify shift lever or push button is in neutral. - Turn key off and wait 2 minutes. - Hold clutch half way to the floor. (If equipped) - Turn key on. - If problem continues, call 1-800-826-HELP (4357) • No engine crank, lever is in neutral and gear display is “N” (neutral). See “Start Enable Relay Contact Test” on page 268. • No engine crank, lever is in neutral and gear display is blank. See “Power-Up Sequence Test” on page 22.. If no problems found, refer to OEM for gear display problem. • No engine crank and lever is NOT in neutral. - Verify shift lever or push button is in neutral. - Turn key off and wait 2 minutes. - Hold clutch half way to the floor. (If equipped) - Turn key on. - If problem continues, call 1-800-826-HELP (4357) • Engine cranks and gear display is blank. Refer to OEM for gear display problem. • Engine cranks and gear display is “N” (neutral), go to Step C. • Fault Code F on gear display, go to Step D. • Neutral “N” on gear display, go to Step B. 2016.01.15 © 2016 Eaton. All rights reserved 3 TRTS0930 Diagnostic Procedures | General Information C Purpose: Confirm the transmission will engage a gear from neutral. 1. Attempt to engage a gear. D Purpose: Check for active or Inactive fault codes. 1. Check for active fault codes. • If gear engaged and drives, go to Step E. Note: If no problem found, refer to OEM for display problem. • If the gear display indicates a solid “gear number” but no drive or reverse, perform “Front Box Control Test” on page 282 • If codes are present, See “Fault Code Isolation Procedure Index” on page 8. • If unable to engage a gear and transmission is an AutoShift, perform “AutoShift Will Not Engage a Gear from Neutral Test” on page 288 • If no codes and gear display is “-” (1 dash) - Verify shift lever or push button is in neutral. - Turn key off. Wait 2 minutes. - Hold clutch half way to the floor. (If equipped) - Turn on key. - If problem continues, call 1-800-826-HELP (4357) • If unable to engage a gear and transmission is an UltraShift DM3, perform “UltraShift DM3 Will Not Engage a Gear from Neutral Test” on page 296 • If unable to engage a gear and transmission is an UltraShift AW3, perform “UltraShift AW3 Clutch Engagement Test” on page 302 See “Front Box Control Test” on page 282. • If no codes and gear display is“--” (2 dashes) or “**” (2 stars), See “Power-Up Sequence Test” on page 22. E Purpose: Drive vehicle and attempt to duplicate a fault code. 1. Record and clear Inactive fault codes. 2. Drive vehicle and attempt to reset code. • If no codes are present, test complete. • If Inactive transmission component or Fault Codes, record codes an call 1-800-826-HELP (4357). • If active transmission component or Fault Codes, See “Fault Code Isolation Procedure Index” on page 8. 4 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Fault Code Retrieval/Clearing Fault Code Retrieval/Clearing Retrieving Fault Codes Manually Retrieve fault codes by enabling the system’s self-diagnostic mode. Note: You can also use a PC- based service tool, such as ServiceRanger to retrieve fault codes. 6. Observe the sequence of flashes on the service light and record the codes. A 1- to 2-second pause separates each stored code, and the sequence automatically repeats after all codes have been flashed. 1 Flash 1. Place the shift lever in neutral. 2. Set the parking brake. SERVICE 3. Turn key on with engine off. Note: If the engine is already running, you may still retrieve codes; however, do not engage the starter if the engine stalls. 4. To Retrieve Active Codes: Key on. Turn key off and on 2 times within five seconds ending with the key on. After 5 seconds, the Service light begins flashing two-digit fault codes. If no faults are active, the service light will flash code 25 (no codes). This is also the procedure to enter, See “Product Diagnostic (PD) Mode” on page 11. for details. Short pause (1/2 sec) Code 13 3 Flashes SERVICE SERVICE SERVICE Long Pause (3-4 sec) Note: An “88” may show up in the dash at key on, which is a normal power-up test of the display. 2x off 2 Flashes on SERVICE 5. To Retrieve Inactive Codes: Turn key on. Turn the key off and on 4 times within five seconds ending with the key in the on position. After 5 seconds, the Service light begins flashing two-digit fault codes. If no faults are active, the service light will flash code 25 (no codes). 4x off • 2016.01.15 SERVICE Short pause (1/2 sec) Code 21 1 Flash SERVICE on Two digit fault codes will be displayed in the gear display. Some vehicle may be equipped with a service light. © 2016 Eaton. All rights reserved 5 TRTS0930 Fault Code Retrieval/Clearing | General Information Clearing Fault Codes Manually The following procedure clears all Inactive fault codes from the TECU’s memory. Active fault codes are automatically cleared when the fault has been corrected. Note: You may use a PC-based service tool, such as ServiceRanger, to clear fault codes. Retrieving Fault Codes with ServiceRanger This section determines if the TECU is communicating on the vehicle's J1939 data link and if the component has set any fault codes. Proper system operation requires the TECU to communicate with other ECUs on the vehicle's J1939 data link. 1. Place shift lever in neutral. Note: This procedure requires ServiceRanger 3.0 or later and an approved RP1210A communications adapter that supports J1939 communications. 2. Set parking brake. 3. Turn key on with engine off. 4. Turn key off and on 6 times within 5 seconds ending with key on. 6x off on Detecting Components 1. Connect the service PC to the vehicle's 9-way J1939 diagnostic port connector with an approved RP1210A communications adapter. 2. Start the ServiceRanger program and verify that a connection has been established with the vehicle's J1939 data link. • Note: If the codes have been successfully cleared, the Service light will come on and stay on for five seconds. The gear display will show 25 (no codes). 5. Turn the key off and allow the system to power down. If the TECU is not detected by ServiceRanger, proceed to the Electrical Pretest procedure to ensure the TECU has power, and that all components are properly connected the vehicle's J1939 data link. Viewing Fault Codes View the Vehicle Fault Codes screen in ServiceRanger and verify if any Active or Inactive codes have been set. 1. If an Active code is present, record the vehicle fault information and proceed to Diagnostic Procedure in this manual for the Active code. Do not clear any codes at this time. 2. If only Inactive codes are present, record the vehicle fault information and clear all fault codes. Road test the vehicle to verify proper operation. 6 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Fault Code Retrieval/Clearing Clearing Fault Codes with ServiceRanger After all repairs have been made and the system is functioning normally, clear all vehicle codes before placing the vehicle back into service. Clearing Fault Code 1. Connect the service PC to the vehicle and start ServiceRanger. 2. View the Vehicle Fault Codes screen and select Clear All. 3. Refresh the screen to verify all Inactive codes have been cleared, and that no Active codes are present. 2016.01.15 © 2016 Eaton. All rights reserved 7 TRTS0930 Fault Code Isolation Procedure Index | General Information Fault Code Isolation Procedure Index Fault Codes SPN 11 PID SID FMI Description 629 254 12 No ECU operation 12 629 254 13, 14 Improper ECU configuration 13 751 231 8, 11 J1939 Shift Control device 14 (without Park Pawl) 751 18, 19 2, 3, 4, 5 Invalid Shift Lever voltage 18, 19 2, 3, 4, 5 Invalid Shift Lever voltage (will show “F” in display) 14 (with Park Pawl) 15 751 18 9 HIL Shift Device communication 16 625 248 2 High Integrity Link (HIL) 17 1321 237 3, 4, 14 Start Enable Relay Coil 21 70 70 14 Auto Neutral Park Brake Switch 22 563 49 9, 14 ABS CAN message fault 25 8 NO CODES 26 522 55 10 Clutch slip 27 788 55 7, 13 Clutch disengagement 28 788 52,55 3, 4, 5, 7 Clutch system 29 969 4, 5 Remote throttle enable 31 1485 2, 3, 4, 5, 14 Momentary Engine Ignition Interrupt Relay (MEIIR) 32 158 43 2 Loss of Switch Ignition power test 33 168 168 4 Low Battery voltage supply 34 168 168 14 Weak Battery voltage supply 35 639 231 2 J1939 communication link 36 639 231 14 J1939 engine message 37 627 251 5 Power supply 41 768 35 7 Range failed to engage 41 769 36 7 Range failed to engage 42 770 37 7 Splitter failed to engage 42 771 38 7 Splitter failed to engage 43 768 35 3, 4, 5 Range High Solenoid Valve 43 769 36 3, 4, 5 Range Low Solenoid Valve 44 787 54 3, 4, 5 Inertia Brake Solenoid Coil 45 787 54 7 Intertia Brake performance 46 770 37 3, 4, 5 Splitter Direct Solenoid Valve 46 771 38 3, 4, 5 Splitter Indirect Solenoid Valve 51 60 2, 3, 4, 10 Rail Position Sensor 372 218 60 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Fault Code Isolation Procedure Index Fault Codes SPN PID 52 59 56 SID FMI Description 59 2, 3, 4, 7 Gear Position Sensor 161 161 2, 3, 4, 5,10 Input Shaft Speed Sensor 57 160 160 2, 3, 4, 5 Main Shaft Speed Sensor 58 191 191 2, 3, 4, 5, 6, 8 Output Shaft Speed Sensor 61 772 39 1, 5, 6, 12 Rail Select Motor 63 773 40 1, 5, 6, 12 Gear Select Motor 68 520274 227 14 Grade Sensor 68 520321 227 13, 14 Grade Sensor 71 560 60 7 Unable to disengage gear 72 772 59 7 Failed to select rail 73 781 58 7 Failed to engage gear 74 518 93 7 Engine speed response fault 74 898 190 7 Engine torque response fault 75* 560 60 14 Power down in gear 81 780 47 7 Gear engagement detected 83 751 18 14 Shift Lever missing 83 752 19 7, 12 Shift Lever missing 84 751 18 13 Shift Control device not configured 84 752 19 13 Park mechanism not calibrated 85 751 18 12 Shift Control device incompatible 99 781 58 14 Direction mismatch * This code will only be set Inactive • J1939 Source Address (SA) for Eaton transmissions is 3 • J1587 Module Identifier (MID) for Eaton transmissions is 130 2016.01.15 © 2016 Eaton. All rights reserved 9 TRTS0930 Symptom-Driven Diagnostics Index | General Information Symptom-Driven Diagnostics Index Symptom Isolation Procedure Unable to shift transmission with Up/Down button Up/Down Button Test Engine starting system complaint Start Enable Relay Contact Test No J1587 communication J1587 Data Link Test Gear display shows a dash Front Box Control Test AutoShift will not engage a gear from Neutral AutoShift Will Not Engage a Gear from Neutral Test UltraShift DM will not engage a gear from Neutral UltraShift DM Will Not Engage a Gear from Neutral Test UltraShift AW3 will not engage a gear from Neutral UltraShift AW3 Clutch Engagement Test AutoShift AS3 shift complaint AutoShift AS3 Shift Complaint Test UltraShift DM shift complaint UltraShift DM Shift Complaint Test UltraShift AW3 shift complaint UltraShift AW3 Shift Complaint Test Shift Lever back light does not work Shift Lever Back Light Test 10 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 General Information | Product Diagnostic (PD) Mode Product Diagnostic (PD) Mode Product Diagnostic (PD) Mode • PD Mode is used to help diagnose Inactive codes that may have been set during normal driving. This diagnostic mode increases the sensitivity of the fault sensing capability This procedure tests loose, degraded and intermittent connections. Use the Active Fault Isolation Procedure to guide you to the wiring and connectors that are associated with the Inactive fault codes. Flex the wiring harness and connectors and attempt to recreate the fault after activating PD Mode. Note: Active codes set during PD Mode will not be stored as Inactive. 7. If a fault is detected, exit PD Mode and perform the corresponding Fault Isolation Procedure. 8. To exit PD Mode, turn the key off. PD Mode is only to be used by a trained service technician in an authorized dealer. This procedure is to be used prior to performing fault isolation procedures for component-type codes when there are no Active codes present. If the fault is detected during PD Mode the gear display will display the active fault. The warning tone will only sound when the fault is active and the tone will stop when the fault is Inactive. The fault will stay in the gear display until the system is powered down. PD Mode works with the following Inactive codes: 11, 13, 14, 15,16, 17, 21, 22, 29, 33, 34, 35, 36, 43, 44, 46, 51, 52, 56, 57, 58, 61, 63, 74, and 99. To enter PD Mode: Note: Vehicle will not start in PD Mode. You must turn vehicle key off to exit PD Mode. 1. Vehicle must be stationary, engine off, set vehicle parking brake. 2. Turn the key off and on 2 times, starting with key on and ending with key on. Note: Dash may display an 88 at key on. This is a normal power-up test of the display. 3. The gear display will flash a 25 then a solid PD (Product Diagnostic Mode) and the mode will be activated. 4. The service light shall flash code 25 once indicating no codes. The service light shall then illuminate solid to indicate PD Mode until such time that an Active code is detected or PD Mode is exited. 5. Refer to PD Mode section in Fault Isolation procedure for the Inactive fault to be diagnosed. 6. PD will remain in gear display until an active fault has been set during the PD Mode fault isolation procedure. 2016.01.15 © 2016 Eaton. All rights reserved 11 TRTS0930 Electrical Pretest | Electrical Pretest Procedures Electrical Pretest Overview The pretest does not relate to any specific fault code, but must be completed before performing Fault Code Isolation table procedures. The pretest verifies the batteries are fully charged. All Generation 3 products require the OEM to supply power to the Electronic Control Unit (ECU). Detection There is no detection process specifically for the basic electrical supply; however, failures of this type are generally detected by the transmission or driver as some other type of fault code or symptom. Fallback There is no fallback for the electrical pretest; however, it may affect other systems. Possible Causes The pretest can be used for: • Low batteries • Starter/Battery connections • Main power harness to the Transmission Electronic Control Unit (TECU) Additional Tools 12 • Basic hand tools • Eaton Test Adapter Kit • Digital Volt/Ohm meter • Troubleshooting Guide • Battery Load tester • ServiceRanger a PC-based service tool © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Electrical Pretest Procedures | Electrical Pretest Component Identification TECU Power Harness OEM is responsible for overcurrent protection on this circuit. + - 1. J1 2. 1. 30 AMP Fuse 2. TECU Connector (Vehicle Interface) 2016.01.15 © 2016 Eaton. All rights reserved 13 TRTS0930 Electrical Pretest | Electrical Pretest Procedures Preferred +12 Volt Connections STARTER BATTERY PLUS 2 GEN 3 ECU BATTERY PLUS + + + + STARTER BATTERY PLUS 1 BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS - - - - STARTER BATTERY M INUS 1 STARTER BATTERY M INUS 2 TWO BATTERY BANKS - TWO BATTERIES PER BANK - DUAL JUMPERS TO STARTER BATTERIES ARE CONNECTED IN PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED BY BATTERY CLOSEST TO STARTER (BOTH PLUS AND MINUS) CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1 + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS STARTER BATTERY M INUS 1 - - - - ONE BATTERY BANK - FOUR BATTERIES BATTERIES ARE CONNECTED IN PARALLEL. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS) CAB BATTERY PLUS MAG RELAY GEN 3 ECU BATTERY PLUS + + + + STARTER BATTERY PLUS 1 BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS - - - - STARTER BATTERY M INUS 1 TWO BATTERY BANKS - TWO BATTERIES PER BANK WITH DISCONNECT BATTERIES ARE CONNECTED IN PARALLEL BY PAIRS - DISCONNECT FOR CAB AND VEHICLE START DISCONNECTED PAIR PROVIDES "DEEP DISCHARGE" CAB COMFORT AND ENTERTAINMENT CAPABILITY. GEN 3 POWER SUPPLIED FROM BATTERY SET CLOSEST TO STARTER AND COMMON TO CAB POWER 14 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Electrical Pretest Procedures | Electrical Pretest Preferred +12 Volt Connections GEN 3 ECU BATTERY MINUS GEN 3 ECU BATTERY PLUS + + + + STARTER BATTERY PLUS BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT - - - - STARTER BATTERY MINUS BATTERY M INUS VEHICLE BATTERY MINUS TWO BATTERY BANKS - BATTERY NEGATIVE DISCONNECT SWITCH BATTERIES ARE DISCONNECTED AT POWER DOWN WHEN VEHICLE STORED INSIDE. GEN 3 POWE R SUPPLIED FROM BATTERY CLOSEST TO THE STARTER. NEGATIVE CONNECTION AT POINT OF VEHICLE CABLE CONNECTION TO DISCONNECT SWITCH GEN 3 ECU BATTERY PLUS POWER DISTRIBUTION MODULE (POWER BUS AND OVER CURRENT DEVICES) STARTER BATTERY PLUS + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS - - - - POWER DISTRIBUTION MODULE BATTERIES ARE CONNECTED IN PARALLEL, POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. CABLES SIZE AND LENGTH OPTIMIZED FOR LOW VOLTAGE DROP CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS Starter Battery Plus + + BATTERY 12 VOLT BATTERY 12 VOLT STARTER - - STARTER BATTERY MINUS GEN 3 ECU BATTERY MINUS STARTER BATTERY CONNECTION GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1 + + BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS 1 - - ONE BATTERY BANK - TWO BATTERIES BATTERIES ARE CONNECTED IN PARALLEL. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS) 2016.01.15 © 2016 Eaton. All rights reserved 15 TRTS0930 Electrical Pretest | Electrical Pretest Procedures Preferred +24 Volt Connections STARTER BATTERY PLUS 2 STARTER BATTERY PLUS 1 GEN 3 ECU BATTERY PLUS + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS - - - - STARTER BATTERY MINUS 1 STARTER BATTERY MINUS 2 TWO BATTERY BANKS - TWO BATTERIES IN SERIES PER BANK - DUAL JUMPERS TO STARTER BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED BY BATTERY CLOSEST TO STARTER (BOTH PLUS AND MINUS) CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1 + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS 1 - - - - ONE BATTERY BANK - FOUR BATTERIES - ONE CABLE PAIR TO STARTER BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS) CAB BATTERY PLUS GEN 3 ECU BATTERY MAG RELAY PLUS STARTER BATTERY PLUS 1 + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS - - - - STARTER BATTERY MINUS 1 TWO BATTERY BANKS - TWO BATTERIES PER BANK WITH DISCONNECT BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS - DISCONNECT FOR CAB AND VEHICLE START - DISCONNECTED PAIR PROVIDES "DEEP DISCHARGE" CAB COMFORT AND ENTERTAINMENT CAPABILITY. GEN 3 POWER SUPPLIED FROM BATTERY SET CLOSEST TO STARTER AND COMMON TO CAB POWER 16 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Electrical Pretest Procedures | Electrical Pretest Preferred +24 Volt Connections GEN 3 ECU BATTERY MINUS GEN 3 ECU BATTERY PLUS + + + + STARTER BATTERY PLUS BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT - - - - STARTER BATTERY MINUS VEHICLE BATTERY MINUS BATTERY MINUS TWO BATTERY BANKS - BATTERY NEGATIVE DISCONNECT SWITCH BATTERIES ARE DISCONNECTED AT POWER DOWN WHEN VEHICLE STORED INSIDE. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO THE STARTER. NEGATIVE CONNECTION AT POINT OF VEHICLE CABLE CONNECTION TO DISCONNECT SWITCH GEN 3 ECU BATTERY PLUS POWER DISTRIBUTION MODULE (POWER BUS AND OVER CURRENT DEVICES) STARTER BATTERY PLUS + + + + BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT BATTERY 12 VOLT GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS - - - - POWER DISTRIBUTION MODULE BATTERIES ARE CONNECTED IN SERIES/PARALLEL, POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. CABLES SIZE AND LENGTH OPTIMIZED FOR LOW VOLTAGE DROP CAB BATTERY PLUS STARTER BATTERY PLUS GEN 3 ECU BATTERY PLUS STARTER GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS STARTER BATTERY CONNECTION GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. 2016.01.15 © 2016 Eaton. All rights reserved 17 TRTS0930 Electrical Pretest | Electrical Pretest Procedures TECU Ignition Circuit 2. 1. J1 3. 35 4. 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 1. TECU connector (vehicle interface) 2. 10 AMP only, manual resetting circuit breaker OR 10 AMP fuse 3. Ignition Key Switch Note: Run to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 4. TECU Connector (vehicle interface) front view From To J1-35 VIGN Battery and ignition power and ground to the TECU must not be switched off during the engine start process. 18 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Electrical Pretest Procedures | Electrical Pretest J1939 Data Link 3. J1939 High J1939 Low D E F C A B J G H + Battery C J1 D B 10 11 F G A 2. 1. 1. TECU connector (vehicle interface) 2. J1587 Data Link 3. 9-Way, for transmission diagnostics J1939 Troubleshooting 1. Check the resistance of the J1939 Data Link. 2. Key off. Measure resistance between the 9-way diagnostic connector Pin C and Pin D and record the reading. The reading should be 60 ohms of resistance (between 50 and 70.) 3. Check resistance between Pin C and Pin A and the resistance between Pin D and Pin A. These two readings should be 10K ohms or greater (open circuit). Note: Pin C = J1939+, Pin D = J1939-, Pin A is a chassis ground • 2016.01.15 If an Inactive data link fault code is being reported by the TECU, See “Product Diagnostic (PD) Mode” on page 11. PDM should be utilized before any further steps are taken. © 2016 Eaton. All rights reserved 19 TRTS0930 Electrical Pretest | Electrical Pretest Procedures Electrical Pretest A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Key off. 1. Locate diagnostic port on Transmission Harness. 2. Remove and clean all battery and battery-to-frame connections. 2. Key on. 3. Remove and clean ground supply to engine ECU. 3. Measure voltage between Pin C and the battery negative post. 4. Inspect starter/battery and inline 30 amp fuse holder connections for corrosion or damaged contacts. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port 5. Measure voltage across batteries. VOLTS • If voltage is 11 to 13 volts on a 12- volt system or 22 to 26 on a 24 volt system, refer to OEM guidelines for battery load test. Repair or replace batteries as required. Go to Step B. B A C D V COM A Battery Negative Post 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) Transmission ECU Batteries – B - Service Bat. + C - Service Bat. A - Service Ignition + + 30 AMP fuse – • If voltage is 0.70 volts or less, go to Step C. + • If voltage is outside of range, repair battery ground supply to Transmission Electrical Control Unit (TECU). Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat this step. 20 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Electrical Pretest Procedures | Electrical Pretest Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Key on. 2. Key on. Warning: Do not load test at the diagnostic port. 3. Measure voltage between Pin B and Pin C. 2. Measure voltage between Pin A and Pin C. Warning! - Do Not Load Test at Diagnostic Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port 4-Pin Diagnostics Port B A B A C D C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 2016.01.15 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is within 0.6 volts of battery voltage, test complete. • If voltage is outside of range, Repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. © 2016 Eaton. All rights reserved 21 Power-Up Sequence Test | Electrical Pretest Procedures TRTS0930 Power-Up Sequence Test Overview This test does not relate to any specific fault code, but must be completed if the self check fails at power-up. Detection The TECU checks the program memory every time the key is turned on. Fallback This causes an In-Place fallback while moving and a self-check failure if it occurs during power-up. Possible Causes This fault code can be caused by any of the following: 22 • Vehicle Harness • Shift Control Device • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Electrical Pretest Procedures | Power-Up Sequence Test Component Identification 4. 1. 2. VOLUME CONTROL 3. R N SERVICE D H SHIFT L Eaton Fuller Transmissions 1. Side view of pushbutton shift control 2. Transmission controller 30-way connector 3. Top view of pushbutton shift control 4. Eaton Cobra Lever 2016.01.15 © 2016 Eaton. All rights reserved 23 TRTS0930 Power-Up Sequence Test | Electrical Pretest Procedures Power-Up Sequence Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. C Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Remove and clean all battery and battery-to- frame connections. 3. Remove and clean ground supply to engine ECU. 3. Measure voltage between Pin B and Pin C. ! Warning: Do not load test at the diagnostic port. • If voltage is within 0.6 volts of battery voltage, go to Step D. 4. Inspect starter/battery and inline 30-amp fuse holder connections for corrosion or damaged contacts. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 5. Measure voltage across batteries. • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat this step. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Key on. 2. Measure voltage between Pin A and Pin C. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair Ignition power supply to ECU. Fuse may be blown. Repeat test. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 24 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 E Electrical Pretest Procedures | Power-Up Sequence Test Purpose: Visually identify if the vehicle is equipped with a shift lever or push button. 1. Is vehicle equipped with an Shift Lever? G Purpose: Visually observe the Service light during key-on power up. 1. Key on. • If vehicle is not equipped with a Shift Lever, go to Step F. 2. Observe Service light. Note: If Service light is flashing, go to Diagnostics Procedure. • If vehicle is equipped with a Shift Lever, go to Step K. • If Service light illuminates for 1 second and turns off, test complete. • If Service light never lights, go to Step H. • If Service light is on steady, replace Shift Control. Go to Step V. F Purpose: Visually identify if the push button is an Eaton built push button or an OEM built J1939 push button. 1. Is it an Eaton Push Button or OEM J1939 Shift Device? • If an Eaton Push Button Shift Control, go to Step G. • If an OEM J1939 Shift Device, refer to OEM for troubleshooting procedures. H Purpose: Measure the voltage supply at the Shift Control device. 1. Key off. 2. Disconnect Shift Control 30-way connector. 3. Key on. 4. Measure voltage between Pin C1 and Pin J3 on the Shift Control 30-way. • If voltage is within 1 volt of battery voltage replace Shift Control. Go to Step V. • If voltage is outside of range, go to Step I. 2016.01.15 © 2016 Eaton. All rights reserved 25 TRTS0930 Power-Up Sequence Test | Electrical Pretest Procedures I Purpose: Verify that a proper ground path is being supplied to the Shift Control Device through the Vehicle Harness and test for a short to ground. K Purpose: Visually identify if the shift lever is an Eaton built shift lever or an OEM built shift lever. 1. Is vehicle equipped with an Eaton supplied Shift Lever or an OEM supplied Shift Lever. 1. Key off. 2. Disconnect negative battery cable. • If Eaton Cobra Lever, go to Step L. 3. Disconnect 38-way Vehicle Harness from TECU. • If OEM Shift Lever, go to Step R. 4. Measure resistance between TECU Pin 25 and Shift Control connector Pin J3 and from then from Pin J3 to ground. • If resistance from Pin 25 to J3 is 0 to 0.3 ohms and resistance from J3 to ground is OL / Open, go to Step J. • If resistance is outside of range, repair the Vehicle Harness. Go to Step V. L Purpose: Visually observe the Service light during key-on power up. 1. Key on. 2. Observe Service light. Note: If Service light is flashing, See “Diagnostic Procedures” on page 3. J Purpose: Measure the resistance of the ignition voltage supply wire to the Shift Control Device through the Vehicle Harness and test for a short to ground. • If Service light illuminates for 1 second and turns off, test complete. • If Service light never comes on, go to Step O. • If Service light is on steady, go to Step M. 1. Measure resistance between TECU Pin 31 and Shift Control connector Pin C1 and then from Pin C1 to ground. • If resistance from Pin 31 to C1 is 0 to 0.3 ohms and resistance from C1 to ground is 10K or OL, replace the TECU. Go to Step V. • If resistance is outside of range, repair the Vehicle Harness. Go to Step V. 26 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 M Electrical Pretest Procedures | Power-Up Sequence Test Purpose: Measure the voltage supply to the Service light during key-on power up. O Purpose: Measure the voltage supply to the Service light during key-on power up. 1. Disconnect Shift Lever 8-way connector. 1. Key off. 2. Key on. 2. Disconnect Shift Lever 8-way connector. 3. Measure voltage at Pin 6 and ground. 3. Key on. • If voltage is within 2 volts of battery voltage for one second, then 0 volts, replace the Eaton Cobra Lever. Go to Step V. 4. Measure voltage between Pin 3 and Pin 6. • If within 1 volt of battery replace Eaton Cobra Lever, go to Step V. • If voltage is constant, go to Step N. N • If voltage is outside of range, go to Step N. Purpose: - Test the Service light voltage supply for short to power through the Vehicle Harness. P Purpose: Verify that a proper ground path is being supplied to the Shift Lever through the Vehicle Harness and test for a short to ground. 1. Key off. 2. Disconnect negative cable. 1. Key off 3. Disconnect 38-way Vehicle Harness connector. 2. Disconnect 38-way Vehicle Harness connector on TECU. 4. Measure resistance between Pin 6 and Pin 4. • If resistance is OL, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) 3. Measure resistance between Pin 3 on the 8-way connector and Pin 25 on the 38-way connector and from Pin 25 to ground. Go to Step V. • If resistance is less than 10K, repair the Vehicle Harness and go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved Note: On Peterbilt disconnect Gear Display, • If resistance between Pin 3 and Pin 25 is 0 to 0.3 ohms and resistance from Pin 25 to ground is OL, go to Step Q. • If resistance is outside of range, repair the Vehicle Harness between the Vehicle Harness 38-way connector Pin 25 and Vehicle Harness 8-way connector Pin 3. Go to Step V. 27 TRTS0930 Power-Up Sequence Test | Electrical Pretest Procedures Q Purpose: Measure the resistance of the ignition voltage supply to the Shift Lever through the Vehicle Harness and test for a short to ground. R Purpose: Measure the voltage supply to the Service light during key-on power up. 1. Key off. 1. Key off. 2. Locate Service light connector on Vehicle Harness. 2. Measure resistance between: - Vehicle Harness 38-way connector Pin 31 and Vehicle Harness 8-way connector Pin 4 - Vehicle Harness 38-way connector Pin 31 and ground 3. Key on. 4. Measure voltage across Pin A and Pin B on the Service light connector • If resistance between Pin 31 and Pin 4 is 0 to 0.3 ohms and if resistance between Pin 31 and ground is OL, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If voltage is within 2 volts of battery voltage for 1 second, then 0 volts, test complete. • If no voltage is measured, go to Step S. • If voltage is within 2 volts of battery voltage continuously, go to Step T. Go to Step V. • If any of the above conditions are not met, replace the Vehicle Harness between Vehicle Harness 38-way connector Pin 31 and Vehicle Harness 8-way connector Pin 4. Go to Step V. 28 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 S Electrical Pretest Procedures | Power-Up Sequence Test Purpose: Measure the resistance of the service light supply wire to the Shift Lever through the Vehicle Harness and test for a short to ground. T Purpose: Test for a short to power at the Shift Lever Service light. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Disconnect negative battery cable. 3. Disconnect TECU 38-way connector. 3. Disconnect 38-way connector. 4. Measure resistance from Pin A of the OEM connector to Pin 23 of the 38-way and from Pin 23 to ground. 4. Measure voltage across Service light connector Pin A and Pin B. • If no voltage is measured, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If resistance from Pin A to Pin 23 is 0 to 0.3 ohms and resistance to ground is 10K or greater, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If voltage is within 2 volts of battery voltage, repair Vehicle Harness as required. Go to Step V. Go to Step V. • If resistance is outside of range, repair the Vehicle Harness and go to Step V. V Purpose: Verify that the system will properly power up. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. • If Power-Up Sequence Test completes, test complete. • If Power-Up Sequence Test fails go to Step A. find error in testing. 2016.01.15 © 2016 Eaton. All rights reserved 29 Fault Code 11 - No TECU Operation | Fault Isolation Procedures TRTS0930 Fault Code 11 - No TECU Operation J1939: SA 3 J1587: MID130 SPN 629 PID FMI 12 FMI 12 Overview This fault code indicates an internal failure of the Transmission Electronic Control Unit (TECU). Detection The TECU checks the program memory every time the key is turned on and throughout operation. If the TECU is able to detect a failure within its own memory, it sets this fault code. Fallback This fault causes a vehicle In Place fallback while moving and a self-check failure if it occurs during power-up. Possible Causes This fault code can be caused by the following: • 30 TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 11 - No TECU Operation Component Identification 1. 1. TECU 2016.01.15 © 2016 Eaton. All rights reserved 31 Fault Code 11 - No TECU Operation | Fault Isolation Procedures TRTS0930 Fault Code 11 - No TECU Operation A Purpose: Check for active or Inactive fault codes 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 11 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If Fault Code 11 is Inactive, test complete. 32 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 11 - No TECU Operation © 2016 Eaton. All rights reserved 33 Fault Code 12 - Improper ECU Configuration | Fault Isolation Procedures TRTS0930 Fault Code 12 - Improper ECU Configuration J1939: SA 3 SPN 629 FMI 13,14 Overview This fault code indicates the Transmission Electronic Control Unit (TECU) is not reading valid information from memory, including the transmission table and calibration values. Detection The TECU checks the configuration every time the key is turned on. If the transmission is not able to detect the proper configuration, it sets this fault code. Fallback This fault causes a power up no crank. Possible Causes This fault code can be caused by the following: • 34 Improper TECU configuration software © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 12 - Improper ECU Configuration Component Identification 1. 1. TECU 2016.01.15 © 2016 Eaton. All rights reserved 35 Fault Code 12 - Improper ECU Configuration | Fault Isolation Procedures TRTS0930 Fault Code 12 - Improper ECU Configuration A Purpose: Check for active or Inactive fault codes. 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 12 is Active, Customer - Call Eaton at 1-800-826-HELP (4357). CSC - Call Technician Service. • If Fault Code 12 is Inactive, test complete. 36 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 12 - Improper ECU Configuration © 2016 Eaton. All rights reserved 37 Fault Code 13 - J1939 Shift Control Device | Fault Isolation Procedures TRTS0930 Fault Code 13 - J1939 Shift Control Device J1587: MID130 J1939: SA 3 PID 231 SPN751 FMI 8, 11 FMI 8, 11 Overview This fault indicates communication has been lost, or does not correspond with the neutral request input from the J1939 Shift Device. When troubleshooting an Inactive code, See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly monitors communication with the J1939 Shift Device. If a neutral request from the J1939 Shift Device does not match the neutral signal or is not received from the J1939 Shift Device, Fault Code 13 is set. Fallback This fault causes a downshift-only fallback. Once the transmission re-engages the start gear, there will be no upshifts as long as the code is active. Possible Causes This fault code can be caused by the following: 38 • OEM J1939 Shift Control Device • Vehicle Harness © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 13 - J1939 Shift Control Device Component Identification 3. 1. 2. J1 16 17 J1939 4. 5. 1. TECU Connector (vehicle interface) 2. Bulkhead connector located at firewall 3. OEM J1939 Shift Device 4. Battery Power (Non-switches power run to battery or starter) 5. Switched Power 2016.01.15 © 2016 Eaton. All rights reserved 39 TRTS0930 Fault Code 13 - J1939 Shift Control Device | Fault Isolation Procedures Fault Code 13 - J1939 Shift Control Device A Purpose: Verify continuity of Neutral Request Signal wire 1. Key off. B Purpose: Verify continuity of Neutral Request Return wire 1. Measure resistance between 38-way connector Pin 17 and corresponding OEM pin at J1939 Shift Device and Pin 17 and ground (see OEM wiring for correct pin location). 2. Disconnect negative battery cable. 3. Disconnect Vehicle Harness 38-way connector. 4. Measure resistance between 38-way connector Pin 16 and corresponding OEM pin at J1939 Shift Device and Pin 16 and ground (see OEM wiring for correct pin location) OHMS V 35 OHMS V 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM 14 35 30 31 32 33 36 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 24 25 26 27 28 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 J1939 36 J1939 V COM 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 21 22 36 A 38 21 22 36 • If resistance is 0 to 0.3 ohms between Pin 16 and the corresponding OEM pin and resistance to ground is 10K ohms or greater, go to Step B. • If resistance is 0 to 0.3 ohms between Pin 17 and the corresponding OEM pin and resistance to ground is 10K ohms or greater, problem exists with the J1939 Shift Device, or J1939 Shift Device power, ground or data link wiring. Contact your OEM for repair strategy. Go to Step V. • If resistance is out of range, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If resistance is out of range, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. Go to Step V. 40 34 OHMS V 29 33 22 21 OHMS 14 32 A 13 37 31 38 37 13 30 15 23 13 37 29 37 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 13 - J1939 Shift Control Device Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 13 appears go to Step A. to find error in testing. • If fault code other than 13 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 41 Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) | Fault Isolation Procedures TRTS0930 Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) J1587: MID 130 J1939: SA 3 SID 18, 19 SPN 751 FMI 2, 3, 4, 5 FMI 2, 3, 4, 5 Overview This fault code indicates an electrical failure of the Eaton Cobra Lever or OEM Shift Lever. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key on and throughout operation the Transmission Electronic Control Unit (TECU) constantly monitors the signal from the Park Pawl Position Sensor. The transmission monitors both sensor signals, if one signal to the TECU is out of range the code will set. Fallback This fault may cause a downshift only fallback mode. The transmission will re-engage the start gear when returned to a stop, but will not upshift as long as the code is active. Possible Causes This fault code can be caused by any of the following: 42 • Eaton Cobra Lever or OEM Shift Lever • Vehicle Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) Component Identification 2. 1. 1. Eaton Cobra Lever 8-way connector 2. TECU 38-way connector 2016.01.15 © 2016 Eaton. All rights reserved 43 TRTS0930 Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) | Fault Isolation Procedures Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) A Purpose: Visually identify the lever type: Eaton or OEM manufactured. 1. Is vehicle equipped with an Eaton supplied Shift Lever or an OEM supplied Shift Lever? • If Eaton Cobra Lever, go to Step B. C Purpose: Verify continuity of auto mode input wire. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect TECU 38-way connector. • If OEM Shift Lever, contact OEM for troubleshooting procedures. 4. Remove tester from Shift Lever 8-way connector. 5. Measure resistance between: - ECU 38-way Pin 15 and Shift Lever 8-way connector Pin 1 - ECU 38-way connector Pin 15 and ground OHMS V B Purpose: Install the Shift Lever tester and monitor Transmission Range in ServiceRanger. Utilize the Shift Lever Tester to verify transmission-lever interface. COM A 37 1 8 2 3 4 7 6 13 5 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 22 21 36 OHMS 1. Key off. V COM A 2. Disconnect Shift Lever 8-way connector. 37 3. Connect Shift Lever tester to the 8-way Shift Lever harness. 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 22 21 36 4. Connect ServiceRanger, a PC-based Service Tool, to diagnostic port. • If resistance between Pin 15 and Pin 1 is 0 to 0.3 ohms and resistance between Pin 15 and ground is 10K ohm or greater, go to Step D. 5. Key on. 6. Select Monitor Data. 7. Observe transmission range selected. • If transmission range selected equals neutral, replace Cobra Lever (only if fault code is Active). Go to Step V. • If any of the above conditions are not met, repair the OEM Vehicle Harness between the TECU and the Eaton Cobra Lever. Go to Step V. • If transmission range selected does not equal neutral, go to Step C. 44 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) Purpose: Verify continuity of manual mode input wire. E Purpose: Verify continuity of common ground wire. 1. Key off. 1. Key off. 2. Measure resistance between: - TECU 38-way Pin 16 and Shift Lever 8-way connector Pin 8 - TECU 38-way connector Pin 16 and ground 2. Measure resistance between: - TECU 38-way Pin 17 and Shift Lever 8-way connector Pin 2 - TECU 38-way connector Pin 17 and ground OHMS OHMS V COM V A 37 1 8 2 7 3 6 4 5 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM 37 21 22 36 1 8 2 7 3 6 4 5 13 14 35 29 33 34 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 33 34 31 32 38 22 21 36 OHMS V A 37 13 14 35 2016.01.15 A 38 OHMS V COM 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 37 38 21 22 36 13 14 35 29 31 32 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 • If resistance between Pin 16 and Pin 8 is 0 to 0.3 ohms and resistance between Pin 16 and ground is 10K ohm or greater, go to Step E. • If resistance between Pin 17 and Pin 2 is 0 to 0.3 ohms and resistance between Pin 17 and ground is 10K ohm or greater, go to Step F. • If any of the above conditions are not met, repair the Vehicle Harness between the Eaton Cobra Lever and TECU. Go to Step V. • If any of the above conditions are not met, repair the Vehicle Harness between the Eaton Cobra Lever and TECU. Go to Step V. © 2016 Eaton. All rights reserved 45 Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) | Fault Isolation Procedures F Purpose: Check for short circuits in the shift lever wiring. V TRTS0930 Purpose: Verify repair. 1. Key off. 1. Key off. 2. Measure resistance between: - Pin 15 and Pin 16 on the TECU 38-way connector. - Pin 15 and Pin 17 on the TECU 38-way connector. - Pin 16 and Pin 17 on the TECU 38-way connector. 2. Reconnect all connectors and the negative battery cable. V 37 13 14 35 4. Clear codes, See “Fault Code Retrieval/Clearing” on page 5. OHMS OHMS V 3. Key on. COM 5. Drive vehicle and attempt to reset the code. A A COM 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 37 22 21 36 13 14 35 31 29 30 33 34 23 24 25 26 27 28 15 16 17 18 19 20 8 9 10 11 12 2 3 4 5 6 7 1 32 38 21 22 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. 36 • If no codes, test complete. OHMS V 37 13 14 35 COM • If code 14 appears, go to Step A. to find error in testing. A 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 22 21 36 • If code other than 14 appears, See “Fault Code Isolation Procedure Index” on page 8. • If resistance on all three is 10K ohm or greater, replace Shift Lever and go to Step V. • If any of the three readings is less than 10K ohm, repair the Vehicle Harness between the Eaton Cobra Lever and TECU. Go to Step V. 46 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (without Park Pawl) © 2016 Eaton. All rights reserved 47 Fault Code 14 - Invalid Shift Lever Voltage (with Park Pawl) | Fault Isolation Procedures TRTS0930 Fault Code 14 - Invalid Shift Lever Voltage (with Park Pawl) J1587: MID 130 J1939: SA 3 SID 18, 19 SPN FMI 2, 3, 4, 5 FMI 2, 3, 4, 5 Overview This fault code indicates a possible failure of the Park Pawl Position Sensor or OEM circuit. The sensor is a 4 wire dual hall effect device. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key on and throughout operation the Transmission Electronic Control Unit (TECU) constantly monitors the signal from the Park Pawl Position Sensor. The transmission monitors both sensor signals, if one signal to the TECU is out of range the code will set. Fallback This fault code will cause the transmission to be stuck in the last known selected position. If the code comes active while in gear, the transmission will a down shift only fallback mode. The transmission will re-engage the start gear when returned to a stop, but will not upshift as long as the code is Active. Possible Causes This fault code can be caused by any of the following: 48 • Vehicle Harness • Park Pawl Position Sensor • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (with Park Pawl) Component Identification 3. 1. 2. 3 4 DEUTSCH X 2 15 16 4 3 17 1 31 2 1 F2 4. 29 37 13 14 35 30 31 32 33 24 25 26 27 34 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 1. Vehicle Harness 38-way Connector 2. 4-Pin Park Pawl Position Sensor Connector (DTM06-4S) 3. Park Pawl Position Sensor 4. TECU Connector Front View (Vehicle Interface) 2016.01.15 4-Way Pin# 38-Way PIN# Type 1 17 Ground 2 31 5 Volt Reference 3 16 Signal 1 4 15 Signal 2 © 2016 Eaton. All rights reserved 49 Fault Code 14 - Invalid Shift Lever Voltage (will show “F” in display) | Fault Isolation Procedures TRTS0930 Fault Code 14 - Invalid Shift Lever Voltage (will show “F” in display) A Purpose: Check for active or Inactive fault codes, noting FMI. C Purpose: Perform Park Pawl Position Sensor calibration. 1. Key on. 1. Perform Park Pawl Position Sensor calibration 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Key on. 3. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. • If Fault Code 14 FMI 2 is active, go to Step B. • If Fault Code 14 FMI 2 is Inactive, go to Step V. • If Fault Code 14 FMI 3, 4 or 5 is active, go to Step D. • If Fault Code 14 FMI 2 is Active, replace Park Pawl Position Sensor. go to Step V. • If Fault Code 14 is Inactive, See “Product Diagnostic (PD) Mode” on page 11. B Purpose: Perform Shift Cable Adjustment procedure. D Purpose: Measure voltage at the Park Pawl Position Sensor. 1. Key off. 1. Key off. 2. Perform shift cable adjustment procedure per OEM guidelines. 3. Key on. 4. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Disconnect the Park Pawl Position Sensor 4-way connector. 3. Key on. 4. At the Park Pawl Position Sensor 4-way connector, measure voltage between Pin 1 and Pin 2. • If Fault Code 14 FMI 2 is Inactive, go to Step V. • If Fault Code 14 FMI 2 is Active, go to Step C. 50 © 2016 Eaton. All rights reserved • If 4.5 to 5.5 volts, go to Step E. • If less than 4.5 volts, go to Step G. • If greater than 5.5 volts, Repair the Vehicle Harness for short to power per OEM guidelines. Go to Step V. 2016.01.15 TRTS0930 E Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (will show “F” in display) Purpose: Verify continuity of Park Pawl Sensor signal wire. F Purpose: Verify continuity of Park Pawl Sensor signal wire. 1. Key off. 1. Key off. 2. Disconnect Park Pawl Position Sensor 4-way connector. 2. Disconnect Park Pawl Position Sensor 4-way connector. 3. Disconnect TECU 38-way Transmission Harness connector. 3. Disconnect TECU 38-way Transmission Harness connector. 4. Measure resistance between Pin 15 and Pin 4. 4. Measure resistance between Pin 16 and Pin 3. 5. Measure resistance between Pin 15 and Ground. 5. Measure resistance between Pin 16 and Ground. • If resistance is 0.0 to 0.3 ohms between Pin 15 and Pin 4 and OL (open circuit) between Pin15 and Ground, go to Step F. • If resistance is greater than 0.3 ohms or OL (open circuit) between Pin 15 and Pin 4 or indicates resistance (short to ground) between Pin 15 and Ground, repair Vehicle Harness for excessive resistance, open or short to ground per OEM guidelines. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved • If resistance is 0.0 to 0.3 ohms between Pin 16 and Pin 3 and OL (open circuit) between Pin 16 and Ground, replace the Park Pawl Position Sensor. Go to Step V. • If resistance is greater than 0.3 ohms or OL (open circuit) between Pin 16 and Pin 3 or indicates resistance (short to ground) between Pin 16 and Ground, repair the Vehicle Harness for excessive resistance, open or short to ground per OEM guidelines. Go to Step V. 51 Fault Code 14 - Invalid Shift Lever Voltage (will show “F” in display) | Fault Isolation Procedures G Purpose: Verify continuity of Park Pawl Sensor ground wire. H TRTS0930 Purpose: Verify continuity of Park Pawl Sensor voltage supply wire. 1. Key off. 1. Key off. 2. Disconnect Park Pawl Position Sensor 4-way connector. 2. Disconnect Park Pawl Position Sensor 4-way connector. 3. Disconnect TECU 38-way Transmission Harness connector. 3. Disconnect TECU 38-way Transmission Harness connector. 4. Measure resistance between Pin 17 and Pin 1. 4. Measure resistance between Pin 31 and Pin 2. 5. Measure resistance between Pin 17 and Ground. 5. Measure resistance between Pin 31 and Ground. • If resistance is 0.0 to 0.3 ohms between Pin 17 and Pin 1 and OL (open circuit) between Pin 17 and Ground, go to Step H. • If resistance is greater than 0.3 ohms or OL (open circuit) between Pin 17 and Pin 1, or indicates resistance (short to ground) between Pin 17 and Ground, repair the Vehicle Harness for excessive resistance, open or short to ground per OEM guidelines. Go to Step V. • If resistance is 0.0 to 0.3 ohms between Pin 31 and Pin 2 and OL (open circuit) between Pin 31 and Ground, (if fault code active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) go to Step V. • If resistance is greater than 0.3 ohms or OL (open circuit) between Pin 31 and Pin 2, or indicates resistance (short to ground) between Pin 31 and Ground, repair the Vehicle Harness for excessive resistance, open or short to ground per OEM guidelines. Go to Step V. 52 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 14 - Invalid Shift Lever Voltage (will show “F” in display) Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset code. 6. Check for codes, see “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete • If Fault Code 14 sets, go to Step A. to find error in testing. • If code other than Fault Code 14 sets, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 53 Fault Code 15 - HIL Shift Device Configuration | Fault Isolation Procedures TRTS0930 Fault Code 15 - HIL Shift Device Configuration J1587: MID 130 J1939: SA 3 SID 18 SPN 751 FMI 9 FMI 9 Overview Controller Area Network (CAN) is a high-speed twisted pair 500K proprietary data link with one 120 ohm resistor at each end of the link. The Transmission Electronic Control Unit (TECU) is connected to the CAN data link at the 38-way connector. This link is used to transmit information to the TECU as well as communicate or receive data from the other modules on the network like the HIL Shift Device. See “Product Diagnostic (PD) Mode” on page 11. Detection Fault Code 15 is set when the TECU fails to receive Shift Device data for 5 continuous seconds, and it is still communicating with other modules on CAN. Fallback This fault causes a downshift only fallback while moving. Once the transmission re-engages the start gear, there will be no upshifts as long as the code is active. If the code is active during power-up a flashing F will appear on the gear display and the TECU will not engage a gear. Possible Causes This fault code can be caused by any of the following: 54 • CAN data link • HIL Shift Device © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 15 - HIL Shift Device Configuration Component Identification 28 27 Vehicle Harness 38-way Connector HIL Data Link F1 F2 25 J3 31 C1 Shift control 30-way connector Vehicle bulkhead connector Shift Control ECU Legend All OEM responsible wiring shown is "typical". Consult specific application. (31) = +12 volt switched from TECU (28, 27) = Communication from and to the TECU (25) = Signal returns, grounds, and general OEM wiring 2016.01.15 © 2016 Eaton. All rights reserved 55 TRTS0930 Fault Code 15 - HIL Shift Device Configuration | Fault Isolation Procedures Fault Code 15 - HIL Shift Device Configuration A Purpose: Check for active and Inactive fault codes and perform electrical pretest. C Purpose: Measure voltage supply to Push Button Shift Controller (PBSC). 1. Key on. 1. Disconnect Shift Control 30-way connector. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Key on. 3. Perform electrical pretest, see “Electrical Pretest” on page 12. 3. Measure voltage on 30-way connector Pin J3 and Pin C1 • If no fault codes found during the electrical pretest and: - if equipped with a Push Button Shift Control, go to Step B. - if equipped with a Cobra Lever or an OEM shift device, configure the Driver Interface Type to the correct shift device type with ServiceRanger. Go to Step V. Volts V COM A 3 2 1 3 2 1 K J H • If issue was repaired during electrical pretest, go to Step V. G F E D C B A B Purpose: Visually inspect vehicle bulkhead connection (if equipped). 1. Key off. 2. Inspect Bulkhead Connector for looseness, corrosion and contamination. • If Bulkhead Connector is found in serviceable condition, go to Step C. • If voltage is within 1.2 volts of battery voltage, go to Step D. • If out of range, go to Step F. • If looseness, corrosion, or contamination is found at the Bulkhead Connector, repair or replace connector per OEM instructions. Go to Step V. 56 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 15 - HIL Shift Device Configuration Purpose: Measure signal voltages on HIL. E Purpose: Confirm the presence of terminating resistors in the HIL. 1. Disconnect Shift Control 30-way connector. 1. Key off. 2. Key on. 2. Measure resistance between Pin F1 and Pin F2 on the Shift Controller 30-way connector. 3. Measure voltage on the Shift Controller 30-way connector pins: - J3 and F1 - J3 and F2 Ohms V COM A 3 2 1 3 2 1 K Volts J H G V COM 3 A 2 1 F K J H G E F D C B A E D C B A 3 2 1 Note: Ensure key is off for a minimum of 2 minutes before proceeding. If unsure, disconnect battery power or remove the 30-amp inline fuse. • If both readings are between 2-3 volts, go to Step E. • If any of the above requirements are not met, go to Step H. • If resistance between Pin F1 and Pin F2 is 110-130 ohms, replace Push Button Shift Control (only if fault code is Active). Go to Step V. • If any of the above requirements are not met, go to Step H. 2016.01.15 © 2016 Eaton. All rights reserved 57 TRTS0930 Fault Code 15 - HIL Shift Device Configuration | Fault Isolation Procedures F Purpose: Verify continuity of ground supply to PBSC and test for short to ground. G Purpose: Verify continuity of power supply to PBSC and test for short to ground. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Measure 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. Disconnect Vehicle Harness 38-way connector. Note: On Peterbilt, disconnect Gear Display. 4. Measure resistance between: OHMS 3 2 1 3 2 1 K V COM 3 A 2 K 1 J J K K H J J H H G G F F E E H G G F F OHMS E D D C C B B OHMS V COM E A D D C C B B A A 3 A A 3 2 V 3 1 2 COM 2 OHMS 1 A 1 V 37 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 13 14 38 35 21 22 29 30 31 32 33 23 24 25 26 27 34 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 21 22 36 36 - Shift Control 30-way connector Pin J3 and Vehicle Harness 38-way connector Pin 25 - Shift Control 30-way connector Pin J3 and ground. • If resistance between Pin J3 and Pin 25 is 0 to 0.3 ohms and if resistance between Pin J3 and ground is OL, go to Step G. • If resistance between Pin C1 and Pin 31 is 0 to 0.3 ohms and resistance between Pin C1 and ground is OL, go to Step H. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. 58 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 H Fault Isolation Procedures | Fault Code 15 - HIL Shift Device Configuration Purpose: Verify continuity of HIL(+) connection to the PBSC. I Purpose: Verify continuity of HIL (-) connection to the PBSC. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 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. 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. • If resistance between Pin F1 and Pin 28 is 0 to 0.3 ohms and if resistance between Pin F1 and ground is OL, go to Step I. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. OHMS 3 2 1 3 2 1 K K J J H H V COM A G G F F E E D D C C B B A A 3 2 OHMS 1 V 37 13 14 35 29 30 23 24 25 26 27 28 15 16 17 18 19 20 31 32 33 34 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 21 22 36 • If resistance between Pin F2 and Pin 27 is 0 to 0.3 ohms and resistance between Pin F2 and ground is OL. If fault code is Active replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 59 Fault Code 15 - HIL Shift Device Configuration | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Key on. 3. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 4. Reconnect all connectors and the negative battery cable. 5. Driving Vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no Fault Codes, test complete. • If Fault Code 15 appears, go to Step A. to find error in testing. • If fault code other than 15 appears, See “Fault Code Isolation Procedure Index” on page 8. 60 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 15 - HIL Shift Device Configuration © 2016 Eaton. All rights reserved 61 Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures TRTS0930 Fault Code 16 - High Integrity Link (HIL) J1587: MID 130 J1939: SA 3 SID 248 SPN 625 FMI 2 FMI 2 Overview This fault code indicates the Transmission Electronic Control Unit (TECU) is unable to communicate with the Push Button Shift Control. Detection Starting at key-on and throughout operation, the TECU constantly monitors the communication with the Push Button Shift Control. If a communication fault occurs for more than 5 seconds, Fault Code 16 is set. Fallback This fault causes a downshift only fallback while moving. Once the transmission re-engages the start gear, there will be no upshifts as long as the code is active. If the code is active during power-up a flashing F will appear on the gear display and the TECU will not engage a gear. Possible Causes This fault code can be caused by any of the following: 62 • Vehicle Harness • TECU • Push Button Shift Control • Charging system • Low batteries • Corroded or loose power supply to TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Component Identification 28 27 Vehicle Harness 38-way Connector HIL Data Link F1 F2 25 J3 31 C1 Shift control 30-way connector Vehicle bulkhead connector Shift Control ECU Legend All OEM responsible wiring shown is "typical". Consult specific application. (31) = +12 volt switched from TECU (28, 27) = Communication from and to the TECU (25) = Signal returns, grounds, and general OEM wiring 2016.01.15 © 2016 Eaton. All rights reserved 63 TRTS0930 Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures Fault Code 16 - High Integrity Link (HIL) A Purpose: Check for active and Inactive fault codes and perform electrical pretest. C Purpose: Measure voltage supply to Push Button Shift Controller (PBSC). 1. Key on. 1. Disconnect Shift Control 30-way connector. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Key on. 3. Perform electrical pretest, see “Electrical Pretest” on page 12. 3. Measure voltage on 30-way connector Pin J3 and Pin C1 • If no fault codes found during the electrical pretest and: - if equipped with a Push Button Shift Control, go to Step B. - if equipped with a Cobra Lever or an OEM shift device, configure the Driver Interface Type to the correct shift device type with ServiceRanger. Go to Step V. Volts V COM A 3 2 1 3 2 1 K J H • If issue was repaired during electrical pretest, go to Step V. G F E D C B A B Purpose: Visually inspect vehicle bulkhead connection (if equipped). 1. Key off. 2. Inspect Bulkhead Connector for looseness, corrosion and contamination. • If Bulkhead Connector is found in serviceable condition, go to Step C. • If voltage is within 1.2 volts of battery voltage, go to Step D. • If out of range, go to Step F. • If looseness, corrosion, or contamination is found at the Bulkhead Connector, repair or replace connector per OEM instructions. Go to Step V. 64 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Purpose: Measure signal voltages on HIL. E Purpose: Confirm the presence of terminating resistors in the HIL. 1. Disconnect Shift Control 30-way connector. 1. Key off. 2. Key on. 2. Measure resistance between Pin F1 and Pin F2 on the Shift Controller 30-way connector. 3. Measure voltage on the Shift Controller 30-way connector pins: - J3 and F1 - J3 and F2 Ohms V COM A 3 2 1 3 2 1 K Volts J H G V COM 3 A 2 1 F K J H G E F D C B A E D C B A 3 2 1 Note: Ensure key is off for a minimum of 2 minutes before proceeding. If unsure, disconnect battery power or remove the 30-amp inline fuse. • If both readings are between 2-3 volts, go to Step E. • If any of the above requirements are not met, go to Step H. • If resistance between Pin F1 and Pin F2 is 110-130 ohms, replace Push Button Shift Control (only if fault code is Active). Go to Step V. • If any of the above requirements are not met, go to Step H. 2016.01.15 © 2016 Eaton. All rights reserved 65 TRTS0930 Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures F Purpose: Verify continuity of ground supply to PBSC and test for short to ground. G Purpose: Verify continuity of power supply to PBSC and test for short to ground. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Measure 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. Disconnect Vehicle Harness 38-way connector. Note: On Peterbilt, disconnect Gear Display. 4. Measure resistance between: - Shift Control 30-way connector Pin J3 and Vehicle Harness 38-way connector Pin 25. - Shift Control Shift Control 30-way connector Pin J3 and ground. 3 2 1 3 2 1 K K J J H H G G F F OHMS OHMS E V COM 3 A 2 1 V COM E A D D C C K K J J B H H G G F F B A A 3 2 OHMS 1 V COM A E E D D C C B B 13 A A 3 2 37 13 14 35 37 OHMS V 3 1 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 2 COM A 1 38 21 14 35 29 30 31 32 33 23 24 25 26 27 34 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 • If resistance between Pin C1 and Pin 31 is 0 to 0.3 ohms and resistance between Pin C1 and ground is OL, go to Step H. 22 36 • If resistance between Pin J3 and Pin 25 is 0 to 0.3 ohms and if resistance between Pin J3 and ground is OL, go to Step G. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. 66 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 H Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Purpose: Verify continuity of HIL(+) connection to the PBSC. I Purpose: Verify continuity of HIL (-) connection to the PBSC. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 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. 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. OHMS J J H H V COM 2 G F F 3 2 1 E D D C C K J J H H B G G A F F COM 1 1 K V 2 A G E 3 OHMS 3 K K B A A 3 2 OHMS 1 V A E E D D C C B B A A 37 13 3 2 37 13 14 3 1 35 29 30 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 14 OHMS 2 1 35 V COM 38 21 29 30 23 24 25 26 27 28 15 16 17 18 19 20 31 32 33 34 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 A • If resistance between Pin F2 and Pin 27 is 0 to 0.3 ohms and resistance between Pin F2 and ground is OL. 22 36 • If resistance between Pin F1 and Pin 28 is 0 to 0.3 ohms and if resistance between Pin F1 and ground is OL, go to Step I. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. 2016.01.15 COM © 2016 Eaton. All rights reserved If fault code is Active replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU. Go to Step V. 67 Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and negative battery cable. 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the code. 6. Check for codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 16 appears, go to Step A. to find error in testing. • If code other than 16 appears, See “Fault Code Isolation Procedure Index” on page 8. 68 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) © 2016 Eaton. All rights reserved 69 Fault Code 17 - Start Enable Relay (SER) Circuit | Fault Isolation Procedures TRTS0930 Fault Code 17 - Start Enable Relay (SER) Circuit J1587: MID 130 J1939: SA 3 SID 237 SPN 629 FMI 3, 4 FMI 3, 4 Overview This fault code indicates an electrical failure of the relay that allows the engine to start after startup conditions are met. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures the circuit. A failure mode of short to battery, short to ground or open circuit is detected. Fallback The start enable relay has no fallback; however, if the failure occurred before the engine was started, it is possible the engine will not start. Possible Causes This fault code can be caused by any of the following: 70 • Start Enable Relay • Vehicle Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 17 - Start Enable Relay (SER) Circuit Component Identification 26 32 4 Run to starter solenoid Vehicle Harness 38-way Connector Run to start signal from ignition switch 30 87 86 85 Start enable relay Trans ECU Legend All OEM responsible wiring shown is "typical". Consult specific application. (30, 87) = Switched ignition (26-87) = Latch into the ECU (4-85) = -12 volt relay source (32-86) = +12 volt relay source 2016.01.15 © 2016 Eaton. All rights reserved 71 TRTS0930 Fault Code 17 - Start Enable Relay (SER) Circuit | Fault Isolation Procedures Fault Code 17 - Start Enable Relay (SER) Circuit A Purpose: Verify SER is correctly wired. Check for active or Inactive fault codes, noting FMI. 1. Key on. C Purpose: Measure resistance of SER through the Transmission Harness. 1. Key off. Note: The SER must be wired according to Eaton GEN III requirements (shown on previous page) for tests to work properly. If wired differently, consult OEM for correct wiring schematic. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Disconnect negative battery cable. 3. Disconnect Vehicle Harness 38-way connector. 4. Measure resistance between Vehicle Harness 38-way connector Pin 32 and Pin 4 and measure resistance between Vehicle Harness 38-way connector Pin 32 and ground. OHMS 3. What FMIs are present? V 37 • If FMI 14 is present, go to Step B. 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 • If FMI 3 or 4 are present, go to Step C. OHMS V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 Vehicle Harness 38-way Connector B Purpose: Visually inspect SER wiring. 1. Inspect OEM SER breakout connector and inspect for misrouted or defective OEM wiring. Inspect per OEM guidelines. • If SER breakout connector is not connected to SER, repair/replace SER per OEM guidelines. Go to Step V. • If resistance between Pin 32 and Pin 4 is 40 to 120 ohms (12-volt system) or 140 to 480 ohms (24-volt system) and resistance between 32 and ground is OL, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If resistance is outside of range, go to Step B. • If circuit has been bypassed, rewire per OEM guidelines. Go to Step V. • If harness is defective, repair the Vehicle Harness per OEM guidelines. Go to Step V. 72 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 17 - Start Enable Relay (SER) Circuit Purpose: Measure resistance of SER at the relay. V Purpose: Verify repair. 1. Remove SER from vehicle dash harness. 1. Key off. 2. Measure resistance between SER Pin 85 and Pin 86. 2. Reconnect all connectors and negative battery cable. 3. Key on. OHMS 87 86 87a 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 85 V COM 5. Drive the vehicle and attempt to reset the code. A 30 6. Check for codes, see “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If resistance is 40 to 120 ohms (12-volt system) or 140 to 480 ohms (24-volt system), repair/replace OEM wiring from TECU to SER. Go to Step C. • If Fault Code 17 appears, go to Step A. to find error in testing. • If fault code other than 17 appears, See “Fault Code Isolation Procedure Index” on page 8. • If resistance is outside of range, replace SER. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 73 Fault Code 21 - Auto Neutral Park Brake Switch | Fault Isolation Procedures TRTS0930 Fault Code 21 - Auto Neutral Park Brake Switch J1587: MID 130 J1939: SA 3 PID 254 SPN 70 FMI 14 FMI 14 Overview An auto neutral feature is provided with this transmission which forces the transmission into neutral in all instances when the parking brake is applied. The OEM installs a normally closed T pressure switch into the existing air line to the parking brake valve. The pressure switch output and return wires are connected to the vehicle interface transmission Electronic Control Unit (TECU) connector. Consult OEM for switch location. This fault code indicates a failure of the switch that reports engagement of the park brake. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Fault Code 21 is set if the switch indicates the park brake is set while the truck is moving for more than 5 seconds, or if the switch state doesn't match the state broadcast on J1939, or if the switch is unstable for more than 5 seconds. Fallback Remote throttle is disabled, and auto neutral may not work. Possible Causes This fault code can be caused by any of the following: 74 • Park brake switch • Park brake wiring • TECU • Park brake hardware not installed • J1939 reporting error © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 21 - Auto Neutral Park Brake Switch Component Identification Front View Transmission ECU Connector (Vehicle Interface) 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 Description From To Pressure Switch Signal Wire Pin 19 Signal Wire Pressure Switch Return Wire Pin 33 Return Wire 2016.01.15 © 2016 Eaton. All rights reserved 22 21 36 75 TRTS0930 Fault Code 21 - Auto Neutral Park Brake Switch | Fault Isolation Procedures Fault Code 21 - Auto Neutral Park Brake Switch A Purpose: Check for active or Inactive fault codes and perform electrical pretest. C Purpose: Remove Park Brake Switch and monitor Park Brake Switch status in ServiceRanger. 1. Key on. 1. Key off. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 2. Disconnect negative battery cable. 3. Perform electrical pretest, see “Electrical Pretest” on page 12. 3. Disconnect the switch. 4. Connect power and key on. • Status changes to released, repair or replace switch per OEM instructions. Go to Step V. • If no issues found during electrical pretest and the fault is still active, go to Step B. • Status remains Applied, go to Step D. • If issue was repaired during electrical pretest, go to Step V. B D Purpose: Monitor park Brake Switch in ServiceRanger. Purpose: Check for short circuits on Park Brake Switch Input wiring. 1. Key off. 1. Ensure vehicle park brake is set and vehicle air system is fully charged. 2. Using the Data Monitoring function in ServiceRanger, note the status of the park brake. 2. Disconnect negative battery cable. 3. Disconnect the Vehicle Harness TECU 38-way connector. 4. Measure resistance between the Vehicle Harness 38-way connector Pin 19 and ground. • Brake is applied, go to Step C. • If resistance between Pin 19 and ground is less than 10K ohm, repair Vehicle Harness per OEM guidelines. Go to Step V. • Brake is released, go to Step E. • Brake is fluctuating between applied and released, go to Step G. Note: If Fault Code 21 goes Inactive when park brake is released, a J1939 reporting error is highly probable. Seek OEM assistance before proceeding to Step C. • If resistance between Pin 19 and ground is greater than 10K ohm or open, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. 76 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 E Fault Isolation Procedures | Fault Code 21 - Auto Neutral Park Brake Switch Purpose: Jump the Park Brake Switch and monitor Park Brake Switch status in ServiceRanger. F Purpose: Verify continuity of Park Brake switch status in ServiceRanger. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Disconnect negative battery cable. 3. Bypass the switch by placing a jumper at the switch connections. 3. Disconnect the Vehicle Harness TECU 38-way connector. 4. Connect power and key on. 4. Measure resistance between the Vehicle Harness 38-way connector Pin 33 and Pin 19. • Status changed to Applied, repair or replace switch per OEM instructions. Go to Step V. Note: The requirement is for a “normally closed” switch. If the park brake status consistently reports contrary values, a “normally open switch” was possibly installed in error. • Status remains Released, go to Step F. • If resistance is greater than 0.3 ohms, repair the Vehicle Harness per OEM guidelines. Go to Step V. • If resistance is 0 to 0.3 ohms, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 77 TRTS0930 Fault Code 21 - Auto Neutral Park Brake Switch | Fault Isolation Procedures G Purpose: Monitor Park Brake Switch status in ServiceRanger. V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Reconnect all connectors and the negative battery cable. 3. Disconnect the switch. 3. Key on. 4. Connect power and key on. • Status changed to Released, repair or replace switch per OEM instructions. Go to Step V. • Status continues changing states, go to Step H. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the fault code. 6. Check for codes, see “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 21 appears, go to Step A. to find error in testing. H Purpose: Check for short circuits in the shift lever wiring. • If fault code other than 21 appears, See “Fault Code Isolation Procedure Index” on page 8. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect the Vehicle Harness 38-way connector. 4. Measure resistance between the Vehicle Harness 38-way connector Pin 33 and Pin 19 and measure the resistance between Pin 19 and ground. • If resistance between Pin 33 and ground or between Pin 33 and Pin 19 is less than 10K ohm, repair the Vehicle Harness per OEM guidelines. Go to Step V. • If resistance between Pin 33 and ground and between Pin 33 and Pin 19 are OL, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. 78 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 21 - Auto Neutral Park Brake Switch © 2016 Eaton. All rights reserved 79 Fault Code 22 - ABS CAN Message Fault | Fault Isolation Procedures TRTS0930 Fault Code 22 - ABS CAN Message Fault J1587: MID 130 J1939: SA 3 SID 254 SPN 563 FMI 9, 14 FMI 9, 14 Overview J1939 is a high-speed twisted pair 250K baud data link with one 120 ohm resistor at each end of the link. The Transmission Electronic Control Unit (TECU) is connected to the J1939 data link at the 38-way vehicle connector. This link is used to transmit information to the TECU as well as communicate or receive data from the other modules on the network like the ABS module. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Fault Code 22 is detected if J1939 communication from the ABS is lost for 5 seconds and other devices are present on J1939. Fallback No Fallback mode; however, Hill Start Aid (HSA) will not function, and the system may attempt a shift during wheel slip events. Possible Causes This fault code can be caused by any of the following: 80 • J1939 datalink • ABS module • ABS module does not support HSA or is not configured with HSA © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 22 - ABS CAN Message Fault Component Identification Transmission ECU +J1939 –J1939 Vehicle Harness 38-way Connector ABS ECM A B Shield C Typical J1939/11 data link harness (OEM supplied) 2016.01.15 © 2016 Eaton. All rights reserved 81 Fault Code 22 - ABS CAN Message Fault | Fault Isolation Procedures TRTS0930 Fault Code 22 - ABS CAN Message Fault A Purpose: Check for active or Inactive fault codes. Contact the vehicle OEM for further directions. 1. Key on. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector • If Fault Code 22 is Active, repair ABS module or data link per OEM guidelines. • If Fault Code 22 is Inactive, test complete. 82 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 22 - ABS CAN Message Fault © 2016 Eaton. All rights reserved 83 TRTS0930 Fault Code 26 - Clutch Slip | Fault Isolation Procedures Fault Code 26 - Clutch Slip J1587: MID 130 J1939: SA 3 SID 55 SPN 522 FMI 10 FMI 10 Overview Fallback This fault code indicates the clutch is not performing as expected. The transmission controller detected excessive clutch slip. This fault causes a downshift only fallback. Once the vehicle is stopped, starting gear and reverse gear can be engaged; however, the fault will clear at power down. Upshifts will be allowed until the fault is detected again. Detection When the transmission is in gear and the clutch is fully engaged, engine speed and input shaft speed are compared. If the engine speed is significantly different from the input shaft speed for a period of one to two seconds, the fault code is set. Clutch Slip Testing Note: It is recommended that the pilot bearing be replaced whenever the clutch is replaced. Note: Refer to Installation Guide TRIG1110 for a list of recommended pilot bearings. Possible Causes This fault code can be caused by any of the following: • Worn or damaged clutch • Clutch abuse • Low clutch torque • Contaminated clutch disks Additional Tools • Clutch jack Note: Secondary clutch failures resulting from conditions such as pilot bearing failures, excessive torsional vibration, or clutch abuse, are not covered under warranty. Note: Record Vehicle Performance Analysis every time a clutch is replaced. 84 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 26 - Clutch Slip Component Identification Driven Disc Driven Disc and Intermediate Plate Clutch Assembly DM Clutch 2016.01.15 © 2016 Eaton. All rights reserved 85 TRTS0930 Fault Code 26 - Clutch Slip | Fault Isolation Procedures Fault Code 26 - Clutch Slip A Purpose: Drive vehicle under load above 1500 RPM. Check for active and Inactive fault codes. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. Start engine. 2. Reconnect all connectors and the negative battery cable. 3. Drive vehicle under load in highest gear possible with engine speed above 1500 RPM. At a steady speed, quickly and fully press and hold the throttle. • If Fault Code 26 is Active, replace clutch. Go to Step V. • If Fault Code 26 is Inactive, test complete. Go to Step V. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If fault code 26 appears go to Step A. to find error in testing. • If fault code other than 26 appears, See “Fault Code Isolation Procedure Index” on page 8. 86 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 26 - Clutch Slip © 2016 Eaton. All rights reserved 87 TRTS0930 Fault Code 27 - Clutch Disengagement | Fault Isolation Procedures Fault Code 27 - Clutch Disengagement J1587: MID 130 J1939: SA 3 SID 55 SPN 788 FMI 7, 13 FMI 7, 13 Overview Fallback The fault code indicates that the clutch has not disengaged as expected. No gear engagement from neutral if the truck is stationary; however, if the TECU determines the vehicle is moving, it will allow a gear engagement from neutral. Detection Starting at key on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures engine RPM and idle torque from the engine. If the engine speed falls significantly below idle or engine torque rises significantly above idle torque upon engaging a start gear, the fault is set. If the vehicle is brought to a stop when in gear and engine speed falls significantly below idle, the fault is set. Clutch Disengagement Test Note: It is recommended that the pilot bearing be replaced whenever the clutch is replaced. Note: Refer to Installation Guide TRIG1110 for a list of recommended pilot bearings. Possible Causes This fault code can be caused by any of the following: • Failed clutch • Clutch thermal abuse • Drive Disc Assembly over-speed • Pilot Bearing failure • Input shaft wear • Lack of lube in Release Bearing and Bushing Additional Tools • Clutch jack Note: Secondary clutch failures resulting from conditions such as pilot bearing failures, excessive torsional vibration or clutch abuse are not covered under warranty. Note: Record Vehicle Performance Analysis every time a clutch is replaced 88 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 27 - Clutch Disengagement Component Identification Driven Disc Driven Disc and Intermediate Plate Clutch Assembly DM Clutch 2016.01.15 © 2016 Eaton. All rights reserved 89 TRTS0930 Fault Code 27 - Clutch Disengagement | Fault Isolation Procedures Fault Code 27 - Clutch Disengagement A Purpose: Monitor and compare engine speed to transmission input shaft speed in ServiceRanger. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. Start engine. 2. Reconnect all connectors and the negative battery cable. 3. Confirm transmission is in neutral. 4. Raise engine speed above 1500 RPM and allow engine to return to idle. 5. Compare engine RPM to input shaft RPM with ServiceRanger, a PC-based Service Tool. Note: Engine idle must be 700 RPM or lower. • If the speeds match at idle and Fault Code 27 is Active, replace the clutch. Go to Step V. 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code. 6. Check for fault codes, “Fault Code Retrieval/Clearing” on page 5 • If they do not match, test complete. • If Fault Code 27 appears go to Step A. to find error in testing. • If code other than 27 appears, See “Fault Code Isolation Procedure Index” on page 8. 90 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 27 - Clutch Disengagement © 2016 Eaton. All rights reserved 91 Fault Code 28 - Clutch System | Fault Isolation Procedures TRTS0930 Fault Code 28 - Clutch System J1587: MID 130 J1939: SA 3 SID 52, 55 SPN 788 FMI 3, 4, 5, 7 FMI 3, 4, 5, 7 Overview This fault code indicates either an electrical or mechanical failure in the WetClutch system. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly monitors this circuit. A failure mode of short to battery, short to ground or open circuit is detected. When the WetClutch is locked after urge to move, engine speed and input shaft speeds are compared. If the engine speed is significantly higher than the input shaft speed for a period of five seconds, the WetClutch is slipping. Fallback There is no fallback mode; however, if the failure mode is open circuit, the engine will be disengaged from the input shaft. Possible Causes This fault code can be caused by any of the following: 92 • TECU • Transmission Harness • Low fluid level • WetClutch system © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 28 - Clutch System Component Identification Transmission Harness Transmission ECU WetClutch Fluid WetClutch System 2016.01.15 © 2016 Eaton. All rights reserved 93 TRTS0930 Fault Code 28 - Clutch System | Fault Isolation Procedures Fault Code 28 - Clutch System A Purpose: Check WetClutch fluid level. B Purpose: Verify continuity of the Clutch Lube Solenoid circuit. 1. Key on. 1. Key off. 2. Place the transmission in neutral. 2. Disconnect the negative battery cable. 3. Allow engine to idle at 700-800 RPM for a minimum of 2 minutes. 3. Disconnect the TECU 30-way connector. Note: Ensure transmission fluid temperature is 60 to 120 degrees F (16 to 49 degrees C). 4. Measure resistance between the Transmission Harness 38-way connector Pin 2 and Pin 3 and between Pin 2 and ground. 4. Check WetClutch fluid level. OHMS V • If fluid level is at or above the COLD-FULL mark, go to Step B. 29 37 13 14 35 • If fluid level is below the COLD-ADD mark, Correct fluid level, go to Step V.. A COM 31 32 33 23 24 25 26 27 28 15 30 16 17 18 19 34 20 7 8 9 10 11 12 1 2 3 4 5 6 38 22 21 36 OHMS V COM A Ground 37 13 14 35 29 30 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 38 22 21 36 Transmission Harness 38-way Connector • If the resistance between 2 and 3 is 6.5 to 9.5 ohms and is resistance from Pin 2 to ground is OL, go to Step C. • If resistance is outside of range, go to Step D. 94 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 28 - Clutch System Purpose: Verify continuity of Clutch Solenoid circuit. 1. Measure resistance between the Transmission Harness 38-way connector Pin 13 and Pin 14 and between Pin 13 and ground. OHMS V COM A 29 37 13 14 31 32 33 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 35 30 34 D Purpose: Verify continuity of hydraulic manifold circuits. 1. Disconnect Transmission Harness located on left side of WetClutch housing. 2. Measure resistance between WetClutch housing connector pins: - 3 and 4 - 1 and 2 38 OHMS OHMS 22 21 36 V COM V A COM A OHMS V COM A Ground 37 13 14 35 29 30 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 4 1 4 1 3 2 3 2 38 21 22 36 Transmission Harness 38-way Connector • If resistance between Pin 13 and Pin 14 is 8.5 to 12 ohms and resistance from Pin 13 to ground is [OL], Replace Transmission (Only if fault code is Active). Go to Step V. • If resistance is less than 10K ohm, go to Step D. 2016.01.15 © 2016 Eaton. All rights reserved • If the resistance between Pin 1 and Pin 2 is 8.5 to 12 ohms and the resistance between Pin 3 and Pin 4 is 6.5 to 9.5 ohms, go to Step E. • If resistance is outside of range, replace transmission, Go to Step V. 95 TRTS0930 Fault Code 28 - Clutch System | Fault Isolation Procedures E Purpose: Test the hydraulic manifold wiring for short circuits. V 1. Measure resistance between WetClutch housing connector pins: - 3 and ground - 1 and ground V COM 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. OHMS OHMS V A 4 1 4 1 3 2 3 2 Purpose: Verify repair. COM A 5. Drive the vehicle and attempt to reset the code. 6. Check for codes, see “Fault Code Retrieval/Clearing” on page 5. GROUND GROUND • If no codes, test complete. • If code 28 appears go to Step A. to find error in testing. • If resistance from Pin 3 to ground and Pin 1 to ground is 10K ohm or greater, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If code other than 28 appears, See “Fault Code Isolation Procedure Index” on page 8. Go to Step V. • If resistance is less than 10K ohm, Replace Transmission. Go to Step V. 96 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 28 - Clutch System © 2016 Eaton. All rights reserved 97 Fault Code 29 - Remote Throttle Enable | Fault Isolation Procedures TRTS0930 Fault Code 29 - Remote Throttle Enable J1587: MID 130 J1939: SA 3 PID 372 SPN 969 FMI 4, 5 FMI 4, 5 Overview This fault indicates an electrical failure of the relay that allows the remote throttle to operate. The relay and wiring are installed by the OEM. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. for more information on troubleshooting Inactive codes. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures the circuit. The fault is set if the TECU detects a bad (open/short) connection for 2 seconds in the wiring from the TECU to the relay. Fallback There is no fallback mode associated with this fault, but the remote throttle will either not work or always work when this fault is active. Possible Causes This fault code can be caused by any of the following: 98 • Remote Throttle relay • Harness • TECU • Software misconfiguration © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 29 - Remote Throttle Enable Component Identification Vehicle Harness 38-way Connector Front View 38-Way Connector Front View Relay connector 30 86 87a 85 REMOTE THROTTLE CONTROL SWITCHES (SET/RESUME) 87 TO ENGINE OR BODY CONTROLLER CRUISE CONTROL INPUT 2016.01.15 © 2016 Eaton. All rights reserved 99 TRTS0930 Fault Code 29 - Remote Throttle Enable | Fault Isolation Procedures Fault Code 29 - Remote Throttle Enable A Purpose: Verify Remote Throttle Enable is functioning per OEM requirements. 1. Follow OEM troubleshooting guidelines to ensure the Remote Throttle Enable Relay has not failed. • If relay is functional, go to Step B.. C Purpose: Test the Remote Throttle Relay circuit for shorts to ground. 1. Key off. 2. Disconnect battery cable. 3. Disconnect the Vehicle Harness 38-way connector. • If relay is not functional (faulted), test complete. Go to Step V. 4. Measure the resistance between Vehicle Harness 38-way connector Pin 24 and ground. • If the resistance between 24 and ground is OL. (If fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) B Purpose: Check for active or Inactive fault codes, noting FMI 1. Key on. Go to Step V. • If resistance is out of range, repair the Vehicle Harness. Go to Step V. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 3. What FMIs are present? Note: The Remote Throttle Enable relay must be wired according to Eaton Gen 3 requirements (shown on previous page) for tests to work properly. If wired differently, consult OEM for correct wiring schematic. • If FMI 4 is present, go to Step C. • If FMI 5 is present, go to Step D. 100 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 29 - Remote Throttle Enable Purpose: Verify continuity of the Remote throttle relay circuit. V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Disconnect battery cable. 2. Reconnect all connectors. 3. Disconnect the Vehicle Harness 38-way connector. 3. Key on. 4. Disconnect the Vehicle Harness from the Throttle Enable Relay. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Measure resistance between Vehicle Harness 38-way connector way 24 and way 86 of the Throttle Enable relay connector. 5. Drive the vehicle and attempt to reset the code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If resistance is 0 to 0.3 ohms, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If no codes, test complete. • If Fault Code 29 appears go to Step A. to find error in testing. • If fault code other than 29 appears, See “Fault Code Isolation Procedure Index” on page 8. Go to Step V. • If resistance is out of range, repair the Vehicle Harness and go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 101 Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test | Fault Isolation Procedures TRTS0930 Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test J1587: MID 130 J1939: SA 3 SID 218 SPN 1485 FMI 2, 3, 4, 5, 14 FMI 2, 3, 4, 5, 14 Overview This fault code indicates an electrical failure of the MEIIR circuit. When troubleshooting an Inactive code, See “Product Diagnostic (PD) Mode” on page 11. Detection The fault is detected during power-up. The Transmission Electronic Control Unit (TECU) checks the MEIIR circuit every time the system is powered up. If the electrical characteristics of the circuit are incorrect, the fault code is set. Fallback There is no fallback associated with this failure. However, if the engine speed flares uncontrollably while the transmission is in a gear, the transmission may not be able to achieve neutral if it is selected due to a torque lock condition. Possible Causes This fault code can be caused by an of the following: 102 • OEM wiring • Mechanical failure in the MEIIR relay • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test Component Identification Transmission ECU Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or 22 Vehicle Harness 38-way Connector 21 20 10 AMP fuse 30 86 85 87 87a Ignition Interrupt Relay Run to Ignition Engine ECM Ignition Interrupt Legend All OEM responsible wiring shown is "typical". Consult specific application. (30, 87a) = +12 volt switched (20-87) (2087) = Signal Sig (21-85) = -12 volt relay source (22-86) = +12 volt relay source 2016.01.15 © 2016 Eaton. All rights reserved 103 TRTS0930 Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test | Fault Isolation Procedures Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test A Purpose: Verify continuity of Momentary Engine Ignition Interrupt Relay (MEIIR) circuit and test for short to ground through Vehicle Interface Harness. Purpose: Verify continuity of MEIIR contact wire and test for short to ground. B 1. Measure resistance between Transmission Vehicle Harness 38-way connector Pin 20 and MEIIR relay connector Pin 87 and from MEIIR relay connector Pin 87 to ground. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect TECU Vehicle Harness 38-way connector. Vehicle Harness 38-way Connector 4. Measure resistance between Vehicle Harness 38-way connector pins 21 and 22 and from Pin 21 to ground. Vehicle Harness 38-way Connector OHMS 30 86 V 87a COM A Front View Relay connector 85 OHMS 87 Ground OHMS 13 14 35 V 30 31 32 33 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 2 3 4 5 COM A 34 22 37 36 13 6 OHMS V 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 85 87 38 21 14 35 37 87a Front View 38-Way Connector 29 1 V 86 Front View 38-Way Connector 37 30 COM 31 32 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 29 30 33 34 38 21 22 36 A 38 21 • If resistance between pins 20 and 87 is 0 to 0.3 ohms and if resistance between Pin 87 and ground is OL, go to Step C. 22 36 • If resistance between pins 21 and 22 is 40 to 120 ohms (24 volt system) and resistance from Pin 21 to ground is OL, go to Step B. • If resistance is outside of the range, repair the Vehicle Harness between the TECU and the MEIIR relay connector. Go to Step V. • If resistance is outside of range, go to Step D. 104 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test Purpose: Test the MEIIR relay for shorts to ground at the relay. D Purpose: Measure resistance across MEIIR relay. 1. Disconnect MEIIR relay from connector 1. Remove MEIIR relay from OEM dash harness. 2. Key on. 2. Measure resistance between MEIIR relay pins 85 and 86. 3. Measure voltage from Pin 30 of the MEIIR relay connector to ground. OHMS VOLTS V V COM COM A A Ground 30 30 86 87a 86 87a 85 87 85 87 Front View Relay connector Front View Relay connector • If voltage is within 0.6 volts of battery voltage replace MEIIR relay. Go to Step E. • If voltage is outside of range repair the Vehicle Harness. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved • If resistance is 40 to 120 ohms (12 volt system) or 140 to 480 ohms (24 volt system) repair OEM wiring from the TECU to the MEIIR relay. Go to Step V. • If resistance is outside of range replace MEIIR relay. Go to Step V. 105 Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test | Fault Isolation Procedures E Purpose: Check for active or Inactive fault codes. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. 2. Key on. • If Fault Code 31 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If Fault Code 31 is Inactive, go to Step V. TRTS0930 3. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 4. Reconnect all connectors and the negative battery cable. 5. Drive vehicle and attempt to reset the code 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 31 appears go to Step A. to find error in testing. • If code other than 31 appears, See “Fault Code Isolation Procedure Index” on page 8. 106 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 31 - Momentary Engine Ignition Interrupt Relay (MEIIR) Test © 2016 Eaton. All rights reserved 107 Fault Code 32 - Loss of Switch Ignition Power Test | Fault Isolation Procedures TRTS0930 Fault Code 32 - Loss of Switch Ignition Power Test J1587: MID 130 J1939: SA 3 PID 43 SPN 158 FMI 2 FMI 2 Overview This fault code indicates a loss of Switched Ignition Power to the Transmission Electronic Control Unit. When troubleshooting an Inactive code, See “Product Diagnostic (PD) Mode” on page 11. Detection The TECU monitors Ignition Power during normal operation. If Ignition power is lost to the TECU during operation a fault is logged. Fallback This fault causes an In-Place fallback while moving. Possible Causes This fault code can be caused by the following: 108 • Ignition switch is turned off during operation • Ignition power is lost during operation © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 32 - Loss of Switch Ignition Power Test Component Identification 10 AMP 12 volt only Manual resetting Or circuit breaker 35 10 AMP fuse Ignition power (switched power) run to main power lead that feeds the ignition bus Vehicle Harness 38-way Connector 2016.01.15 © 2016 Eaton. All rights reserved 109 TRTS0930 Fault Code 32 - Loss of Switch Ignition Power Test | Fault Isolation Procedures Fault Code 32 - Loss of Switch Ignition Power Test A Purpose: Measure batter voltage. Visually inspect the batteries, inline fuse, power, ground supplies to TECU. B Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and inline fuse holder connections for integrity. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS VOLTS – V COM + B A C D V COM A Battery Negative Post A – 4-way + 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage between Pin C and battery negative post is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat this step. 110 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 32 - Loss of Switch Ignition Power Test Purpose: Measure battery voltage at 4-way diagnostic port. D Purpose: Measure ignition voltage at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step V. • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. V Purpose: Verify repair. 1. Drive vehicle and attempt to reset codes. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If code 32 is Inactive, This code indicates a loss of ignition switched power to the TECU during operation. Verify the key was not turned off during operation. Inspect ignition circuit for intermittent open. 2016.01.15 © 2016 Eaton. All rights reserved 111 Fault Code 33 - Low Battery Voltage Supply | Fault Isolation Procedures TRTS0930 Fault Code 33 - Low Battery Voltage Supply J1587: MID 130 J1939: SA 3 PID 168 SPN 168 FMI 4 FMI 4 Overview This fault code indicates that the vehicle battery power supply to the Transmission Electronic Control Unit (TECU) is below 7 volts. When troubleshooting an Inactive code, See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the TECU constantly measures vehicle voltage. If voltage is below 7 volts for more than 1 second, Fault Code 33 will be set and the service light will flash. Fallback If this fault occurs while moving, it causes a 1-speed fallback. Once the vehicle is stopped, the starting gear and reverse can be engaged Possible Causes This fault code can be caused by any of the following: 112 • Corroded or loose power supply to TECU • Low batteries • Damaged Vehicle Harness • TECU • Charging system © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 33 - Low Battery Voltage Supply Component Identification Batteries Vehicle Charging System – – 2016.01.15 © 2016 Eaton. All rights reserved + + 113 TRTS0930 Fault Code 33 - Low Battery Voltage Supply | Fault Isolation Procedures Fault Code 33 - Low Battery Voltage Supply A Purpose: Measure battery voltage. Visually inspect batteries, inline fuse, power and ground supplies to TECU. B Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS B A C D • If voltage is outside of range, repair or replace batteries, charging system as required. Repeat this step. V COM A Battery Negative Post 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 114 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 33 - Low Battery Voltage Supply Purpose: Measure battery voltage at 4-way diagnostic port. D Purpose: Measure ignition voltage at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 2016.01.15 B - Service Bat. + C - Service Bat. A - Service Ignition + © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. 115 Fault Code 33 - Low Battery Voltage Supply | Fault Isolation Procedures E TRTS0930 Purpose: Check for active and Inactive fault codes. 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 33 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If Fault Code 33 is Inactive, clear codes and go to Step V. V Purpose: Verify repair. 1. Key off. 2. Key on. 3. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 4. Reconnect all connectors and the negative battery cable. 5. Drive vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 33 appears go to Step A. to find error in testing. • If code other than 33 appears, See “Fault Code Isolation Procedure Index” on page 8. 116 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 33 - Low Battery Voltage Supply © 2016 Eaton. All rights reserved 117 Fault Code 34 - Weak Battery Voltage Supply | Fault Isolation Procedures TRTS0930 Fault Code 34 - Weak Battery Voltage Supply J1587: MID 130 J1939: SA 3 PID 168 SPN 168 FMI 14 FMI 14 Overview This fault indicates the vehicle is supplying weak battery voltage to the transmission for 10 seconds. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures vehicle voltage. If voltage is below 9 volts for more than 10 seconds, Fault Code 34 will be set. The service light will not flash. Fallback If this fault occures while moving, it causes a 1-speed fallback. Once the vehicle is stopped, the starting gear and reverse can be engaged Possible Causes This fault code can be caused by any of the following: 118 • Corroded or loose power supply to TECU • Low batteries • Damaged Vehicle Harness • TECU • Charging system © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 34 - Weak Battery Voltage Supply Component Identification Batteries Vehicle Charging System – – 2016.01.15 © 2016 Eaton. All rights reserved + + 119 TRTS0930 Fault Code 34 - Weak Battery Voltage Supply | Fault Isolation Procedures Fault Code 34 - Weak Battery Voltage Supply A Purpose: Measure battery voltage. Visually inspect batteries, inline fuse, power and ground supplies to TECU. B Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS B A C D • If voltage is outside of range, repair or replace batteries, charging system as required. Repeat this step. V COM A Battery Negative Post 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage between is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 120 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 34 - Weak Battery Voltage Supply Purpose: Measure battery voltage at 4-way diagnostic port. D Purpose: Measure ignition voltage at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 2016.01.15 B - Service Bat. + C - Service Bat. A - Service Ignition + © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. 121 Fault Code 34 - Weak Battery Voltage Supply | Fault Isolation Procedures E TRTS0930 Purpose: Check for active and Inactive fault codes. 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 34 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If Fault Code 34 is Inactive, clear codes. Go to Step V. V Purpose: Verify repair. 1. Key off. 2. Key on. 3. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 4. Reconnect all connectors and the negative battery cable. 5. Drive vehicle and attempt to reset the code 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 34 appears go to Step A. to find error in testing. • If code other than 34 appears, See “Fault Code Isolation Procedure Index” on page 8. 122 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 34 - Weak Battery Voltage Supply © 2016 Eaton. All rights reserved 123 Fault Code 35 - J1939 Communication Link | Fault Isolation Procedures TRTS0930 Fault Code 35 - J1939 Communication Link J1587: MID 130 J1939: SA 3 SID 231 SPN 639 FMI 2 FMI 2 Overview This fault code indicates the Transmission Electronic Control Unit (TECU) failed to communicate with the engine over the J1939 data link. If you have an Active Fault Code 35 with an UltraShift DM transmission and the engine will crank but not start, please check the OEM supplied MEIIR (Momentary Engine Ignition Interrupt Relay) circuit. Ensure that the engine has proper ignition voltage. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Seventy-five seconds after key-on and throughout the operation, the TECU constantly monitors the communication with the engine ECM. If a communication fault occurs for more than 5 seconds, and no other devices are present, Fault Code 35 is set. Fallback If the fault occurs during power-up the transmission will go into AutoSelect mode. If the fault occurs while moving, it causes an in-place fallback. The transmission will remain in the gear that was engaged when the failure occurred. Once the vehicle stops, start and reverse gears can be selected and the transmission will operate in AutoSelect mode. Possible Causes This fault can be caused by any of the following: 124 • J1939 Data Link • Engine ECM • Vehicle Harness or Connections • Engine Harness or Connections • Excessive radio interference • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 35 - J1939 Communication Link Component Identification Transmission ECU +J1939 Engine ECM –J1939 Vehicle Harness 38-way Connector A B Shield C Typical J1939/11 data link harness (OEM supplied) 2016.01.15 © 2016 Eaton. All rights reserved 125 TRTS0930 Fault Code 35 - J1939 Communication Link | Fault Isolation Procedures Fault Code 35 - J1939 Communication Link A Purpose: Verify continuity of J1939 Data Link low (-) circuit and test for short to ground. B Purpose: Verify continuity of J1939 Data Link (+) circuit and test for short to ground. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Measure resistance between: - Vehicle Harness 38-way connector Pin 3 and engine ECM pin number (see OEM J1939 wiring for (+) J1939) - Vehicle Harness 38-way Pin 3 and ground 3. Disconnect Vehicle Harness 38-way connector. 4. Disconnect engine ECM connector which contains the J1939 Data Link. 5. Measure resistance between: - Vehicle Harness 38-way connector Pin 2 and engine ECM pin number (see OEM wiring for (-) J1939). - Vehicle harness 38-way Pin 2 and ground. Front View 38-Way Connector OHMS 29 37 13 14 35 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 38 V COM A 22 21 See OEM J1939 Wiring for correct pin on ECM 36 OHMS 37 29 33 34 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V 13 14 35 COM A 22 21 36 Vehicle Harness 38-way Connector Front View 38-Way Connector OHMS 29 37 31 32 33 23 24 25 26 27 28 15 30 16 17 18 19 34 20 7 8 9 10 11 12 1 2 3 4 5 6 29 30 31 32 33 34 38 V 13 14 35 COM A 22 21 36 See OEM J1939 Wiring for correct pin on ECM OHMS 37 13 14 35 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V 21 COM A 22 36 Vehicle Harness 38-way Connector • If resistance between Pin 2 and engine ECM pin is 0 to 0.3 ohms and if resistance between Pin 2 and ground is OL, go to Step B. • If resistance between Pin 3 and engine ECM pin number is 0 to 0.3 ohms, and if resistance between Pin 3 and ground is OL, - If equipped with J1939 Lite, go to Step D. - If not equipped with J1939 Lite, go to Step C. • If resistance is outside of range, repair J1939 Data Link Harness between engine ECM and TECU. Go to Step V. • If resistance is outside of range, repair J1939 Data Link Harness between engine ECM and TECU. Go to Step V. 126 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 35 - J1939 Communication Link Purpose: Verify continuity of J1939 Data Link Shield (+) wire (if equipped) and test for short to ground. D Purpose: Confirm the presence of terminating resistors in the J1939 Data Link. 1. Key off. 1. Key off. 2. Measure resistance between Vehicle Harness 38-way connector Pin 1 and engine ECM pin number (see OEM J1939 wiring for J1939 shield). 2. Measure resistance between Vehicle Harness 38-way connector Pin 2 and Pin 3. Note: En sure the volt/ohm meter is on the proper scale (around 200 ohm) Front View 38-Way Connector OHMS 37 29 30 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 14 35 Vehicle Harness 38-way Connector Front View 38-Way Connector 38 V 13 COM A 22 21 36 OHMS See OEM J1939 Wiring for correct pin on ECM 37 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V 13 14 35 COM A 22 21 36 Vehicle Harness 38-way Connector • If resistance between Pin 1 and engine ECM pin number is 0 to 0.3 ohms, go to Step D. • If resistance is outside of range, Repair J1939 Data Link Harness between engine ECM and TECU. Go to Step V. • If resistance between Pin 2 and Pin 3 is between 50 to 70 ohms, go to Step V. • If resistance is more than 70 ohms, one or more of the terminating resistors on the J1939 Data Link Harness is either missing or out of range, repair OEM J1939 Data Link Harness. Go to Step V. • If resistance is less than 50 ohms, repair the J1939 Data Link between the engine ECM and the TECU. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 127 Fault Code 35 - J1939 Communication Link | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Key on. 3. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 4. Reconnect all connectors and the negative battery cable. 5. Drive vehicle and attempt to reset the code 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 35 appears go to Step A. to find error in testing. • If code other than 35 appears, See “Fault Code Isolation Procedure Index” on page 8. 128 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 35 - J1939 Communication Link © 2016 Eaton. All rights reserved 129 Fault Code 36 - J1939 Engine Message | Fault Isolation Procedures TRTS0930 Fault Code 36 - J1939 Engine Message J1587: MID 130 J1939: SA 3 SID231 SPN 639 FMI 14 FMI 14 Overview This fault code indicates the Transmission Electronic Control Unit (TECU) has communicated with another ECU, but is unable to communicate with the engine ECU over the J1939 data link. If you have an Active Fault Code 36 with an UltraShift DM transmission and engine will crank but not start, please check the OEM supplied MEIIR (Momentary Engine Ignition Interrupt Relay) circuit and see that the engine has proper ignition voltage. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection The fault is detected if J1939 communication from the engine is lost for 5 seconds and other devices are present on J1939. Fallback If the fault occurs during power-up, the transmission will go into AutoSelect mode. If the fault occurs while moving, it causes an in-place fallback and the transmission will remain in the gear that was engaged when the failure occurred. Once the vehicle stops, start and reverse gears can be selected and the transmission will operate in AutoSelect mode. Possible Causes This fault can be caused by any of the following: 130 • J1939 Data Link • Engine ECM • Vehicle Harness or Connections • Engine Harness or Connections • Excessive radio interference • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 36 - J1939 Engine Message Component Identification Transmission ECU +J1939 –J1939 Vehicle Harness 38-way Connector Engine ECM A B Shield C Typical J1939/11 data link harness (OEM supplied) 2016.01.15 © 2016 Eaton. All rights reserved 131 TRTS0930 Fault Code 36 - J1939 Engine Message | Fault Isolation Procedures Fault Code 36 - J1939 Engine Message A Purpose: Verify continuity of J1939 Data Link Low (-) circuit and test for short to ground. B Purpose: Verify continuity of J1939 Data Link High (+) circuit and test for short to ground. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Measure resistance between: - Vehicle Harness 38-way connector Pin 3 and engine ECM pin # (see OEM wiring for (+)J1939) - Vehicle Harness 38-way connector Pin 3 and ground 3. Disconnect Vehicle Harness 38-way connector. 4. Disconnect engine ECM connector which contains the J1939 Data Link. 5. Measure resistance between: - Vehicle Harness 38-way connector Pin 2 and engine ECM pin # (see OEM wiring for (-) J1939). - Vehicle Harness 38-way connector Pin 2 and ground. Front View 38-Way Connector OHMS 29 37 13 14 35 30 31 32 33 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 34 12 1 2 3 4 5 6 34 38 V A See OEM J1939 Wiring for correct pin on ECM 36 OHMS 37 29 31 32 33 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V 13 14 35 Front View 38-Way Connector COM 22 21 COM A 22 21 36 Vehicle Harness 38-way Connector GROUND OHMS 37 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 29 30 31 32 33 34 38 V 13 14 35 COM A 22 21 36 See OEM J1939 Wiring for correct pin on ECM OHMS 37 13 14 35 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V COM A 22 21 36 Vehicle Harness 38-way Connector GROUND • If resistance between Pin 2 and engine ECM pin # (see OEM wiring for (-)J1939) is 0 to 0.3 ohms and if resistance between Pin 2 and ground is OL, go to Step B. • If resistance is outside of range, repair J1939 Data Link Harness between engine ECM and TECU. Go to Step V. 132 © 2016 Eaton. All rights reserved • If resistance between Pin 3 and engine ECM pin # (see OEM wiring for (+)J1939) is 0 to 0.3 ohms and if resistance between Pin 3 and ground is OL, - If equipped with J1939 Lite, go to Step D. - If not equipped with J1939 Lite, go to Step C. • If resistance is outside of range, repair J1939 Data Link Harness between Engine ECM and TECU. Go to Step V. 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 36 - J1939 Engine Message Purpose: Verify continuity of J1939 Data Link Shield (+) wire (if equipped) and test for short to ground. D Purpose: Confirm the presence of terminating resistors in the J1939 Data Link. 1. Key off. 1. Key off. 2. Measure resistance between Vehicle Harness 38-way connector Pin 1 and engine ECM pin # (see OEM wiring for J1939 shield). 2. Measure resistance between Vehicle Harness 38-way connector Pin 2 and Pin 3. Note: Make sure the volt/ohm meter is on the proper scale (around 200 ohm scale). Front View 38-Way Connector OHMS 37 29 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 30 8 9 10 11 12 1 2 3 4 5 6 31 32 14 35 Vehicle Harness 38-way Connector Front View 38-Way Connector 38 V 13 COM A 22 21 36 OHMS See OEM J1939 Wiring for correct pin on ECM 37 29 33 34 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 38 V 13 14 35 COM A 22 21 36 Vehicle Harness 38-way Connector • If resistance between Pin 1 and engine ECM pin # (see OEM wiring for J1939 shield) is 0 to 0.3 ohms, go to Step D. • If resistance is outside of range, repair J1939 Data Link Harness between engine ECM and TECU. Go to Step V. • If resistance between Pin 2 and Pin 3 is between 50 to 70 ohms, go to Step V. • If resistance is more than 70 ohms, 1or more of the terminating resistors on the J1939 data link harness is either missing or out of range. Repair J1939 Data Link Harness. Go to Step V. • If resistance is less than 50 ohms, repair the J1939 Data Link between the Engine ECM and the TECU. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 133 Fault Code 36 - J1939 Engine Message | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 36 appears go to Step A. to find error in testing, • If fault code other than 36 appears, See “Fault Code Isolation Procedure Index” on page 8. 134 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 36 - J1939 Engine Message © 2016 Eaton. All rights reserved 135 Fault Code 37 - Power Supply | Fault Isolation Procedures TRTS0930 Fault Code 37 - Power Supply J1587: MID 130 J1939: SA 3 SID 251 SPN 627 FMI 5 FMI 5 Overview This fault code indicates excessive resistance has been detected between the power supply source (battery or starter) and the Transmission Electronic Control Unit (TECU). Detection The resistance on the TECU power supply circuit is measured during each shift. If the resistance is greater than 0.4 ohms this fault will set. Fallback No fallback mode. Possible Causes This fault code can be caused by the following: 136 • Corrosion on power supply or ground supply connections or wires to the TECU • Corrosion in fuse holder for TECU power supply. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 37 - Power Supply Component Identification Transmission ECU 30 AMP fuse Battery power (non-switched power) run to starter or batteries 2016.01.15 © 2016 Eaton. All rights reserved 137 TRTS0930 Fault Code 37 - Power Supply | Fault Isolation Procedures Fault Code 37 - Power Supply A Purpose: Measure battery voltage. Visually inspect batteries, inline fuse, power and ground supplies to the TECU. B Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS VOLTS – + B A C D V COM A Battery Negative Post V COM A – + 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. • If voltage is outside of rangeRepair or replace batteries and charging system as required. Repeat this step. 138 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 37 - Power Supply Purpose: Measure battery voltage at 4-way diagnostic port. D Purpose: Measure ignition voltage at 4-way diagnostic port. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of rang, repair battery power supply to TECU. Fuse may be blown. Repeat test. 2016.01.15 B - Service Bat. + C - Service Bat. A - Service Ignition + © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. 139 TRTS0930 Fault Code 37 - Power Supply | Fault Isolation Procedures E Purpose: Visually inspect batteries, inline fuse, power and ground supplies to the TECU. V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Clean and reconnect all connectors. 3. Disconnect the Vehicle Harness 38-way. 3. Key on. 4. Inspect main power 38-way connector terminals Pin 36 and Pin 38, in-line fuse holder, and power supply connections for integrity and corrosion. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. Transmission ECU 6. Check for codes See “Fault Code Retrieval/Clearing” on page 5. Batteries – 5. Drive vehicle and attempt to reset the code + • If no codes, test complete. 30 AMP fuse – + • If Fault Code 37 appears go to Step A. to find error in testing. Vehicle Harness 38-way Connector 29 37 13 14 35 30 31 33 34 23 24 25 26 27 28 15 16 17 32 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 • If fault code other than 37 appears, See “Fault Code Isolation Procedure Index” on page 8. 22 21 36 Front View 38-Way Connector • If no problem found, go to Step V. • If problem is found, repair power/ground path for the main power supply. Go to Step V. 140 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 37 - Power Supply © 2016 Eaton. All rights reserved 141 Fault Code 41 - Range Failed to Engage | Fault Isolation Procedures TRTS0930 Fault Code 41 - Range Failed to Engage J1587: MID 130 J1939: SA 3 PID 35, 36 FMI 7 SPN 768, 769 FMI 7 Overview This fault code indicates the transmission is unable to complete a shift across the range. The range is either stuck in high or low, or cannot complete engagement into high or low. Detection The transmission attempts the same range shift 5 consecutive times and determines the shift cannot be completed based on the speeds across the back box. Fallback This fault causes a current range fallback and the transmission stays in either low range or high range. When the vehicle comes to a stop, an attempt to shift into low range is made. Possible Causes This fault code can be caused by any of the following: • Low air pressure • Contaminated air supply • Air leak • Range Solenoid Valve • Range Synchronizer • Range Actuator / Cylinder / Piston / Yoke • Range Cover Additional Tools • 142 Two 0-100 PSI Air pressure gauges © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 41 - Range Failed to Engage Component Identification Range system 2016.01.15 © 2016 Eaton. All rights reserved 143 TRTS0930 Fault Code 41 - Range Failed to Engage | Fault Isolation Procedures Fault Code 41 - Range Failed to Engage A Purpose: Measure vehicle air supply pressure. 1. Key off. 2. Install a 0-100 PSI air pressure gauge in the regulated test port of the air filter/regulator. C Purpose: Verify air filter/regulator operation. 1. Read air pressure gauge installed at the regulated port. • If air pressure is in range is 55 to 65 PSI (or 75 to 80 PSI for UltraShift PLUS LAS Models), go to Step E. 3. Start engine and allow air pressure to build to governor cut-off. • If air pressure is outside of range, go to Step D. 4. Monitor the vehicle air pressure gauge on the dash. 0-100 PSI D Regulated test port • If air pressure cuts off at 90 to 120 PSI, go to Step B. 1. Remove air supply line to the air filter /regulator and check airflow. • If air pressure is outside of range, repair the air system as required. Repeat this step. B Purpose: Confirm air flow to the filter regulator supply port. • If air flows from the supply line, repair Air Filter/Regulator. Go to Step C. • If air does not flow from the supply line, replace Air Filter Regulator. Go to Step C. Purpose: Measure vehicle maintains air supply pressure. 1. Key off. 2. Monitor the vehicle air pressure gauge on the dash. • If vehicle maintains air pressure, go to Step C. • If vehicle loses air pressure, repair the air system as required. Repeat this step. 144 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 E Fault Isolation Procedures | Fault Code 41 - Range Failed to Engage Purpose: Measure low range air pressures. F Purpose: Measure high range air pressures. 1. Key off. 1. Key on. 2. Install two 0-100 PSI air pressure gauges into the range cover diagnostic ports. 2. With Shift Control, select the highest reverse gear available by pressing the up-shift button/arrow, then select neutral. 3. Start vehicle. Allow air pressure to build to governor cut-off. 4. Turn off engine, but leave key in on position. 5. With Shift Control, select reverse, then select neutral. Note: Allow 5 minutes for checking the air pressure after shifting the transmission to neutral. Note: Monitor gear display after selecting the highest reverse gear available and confirm gear position has changed in the display. A gear change is required to energize the range solenoid. HIGH range 0-100 PSI gauge LOW range 0-100 PSI gauge Note: Monitor gear display after selecting reverse, then neutral and confirm gear position has changed in the display. A gear change is required to energize the range solenoid. HIGH range 0-100 PSI gauge LOW range 0-100 PSI gauge • If high range gauge - 55 to 65 PSI for Non-LAS Models - 75 to 80 PSI for UltraShift PLUS LAS Models If low range gauge - 0 PSI for all others Repair mechanical range system as required. go to Step V., • If low range gauge is 55 to 65 PSI for Non-LAS Models (75 to 80 PSI for UltraShift PLUS LAS Models) and if high range gauge is 0 PSI, go to Step F. • If air pressure gauges do not read as shown above, replace Range Valve. Go to Step V. • If air pressure gauges do not read as shown above, replace Range Valve. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 145 Fault Code 41 - Range Failed to Engage | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Remove all gauges. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 41 appears go to Step A. to find error in testing. • If fault code other than 41 appears, See “Fault Code Isolation Procedure Index” on page 8. 146 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 41 - Range Failed to Engage © 2016 Eaton. All rights reserved 147 Fault Code 42 - Splitter Failed to Engage | Fault Isolation Procedures TRTS0930 Fault Code 42 - Splitter Failed to Engage J1587: MID 130 J1939: SA 3 PID 37, 38 FMI 7 SPN 770, 771 FMI 7 Overview This fault code indicates the transmission is unable to complete a shift across the Splitter. The Splitter is either stuck in high or low, or cannot complete engagement into high or low. Detection The transmission attempts the same splitter shift 3 consecutive times and determines the shift cannot be completed based on the speeds across the back box. Fallback This fault causes a current splitter fallback and the transmission stays in either low split or high split. Possible Causes This fault code can be caused by any of the following: • Low air pressure • Contaminated air supply • Air leak • Splitter Solenoid Valve • Splitter Actuator / Cylinder / Piston / Yoke • Splitter Clutch Additional Tools • 148 Two 0-100 PSI air pressure gauges © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 42 - Splitter Failed to Engage Component Identification Splitter system Reduction Alternate View - Combination Cylinder Models 2016.01.15 © 2016 Eaton. All rights reserved 149 TRTS0930 Fault Code 42 - Splitter Failed to Engage | Fault Isolation Procedures Fault Code 42 - Splitter Failed to Engage A Purpose: Measure vehicle air supply pressure. 1. Key off. 2. Install a 0-100 PSI air pressure gauge in the regulated test port of the air filter/regulator. C Purpose: Verify air filter/regulator operation. 1. Read air pressure gauge installed at the regulated port. • If air pressure is 55 to 65 PSI, go to Step E. 3. Start engine and allow air pressure to build to governor cut-off. • If air pressure is outside of range, go to Step D. 4. Monitor the vehicle air pressure gauge on the dash. 0-100 PSI D Regulated test port B Purpose: Confirm air flow to the filter regulator supply port. 1. Remove air supply line to the air filter /regulator and check airflow. • If air pressure cuts off at 90 to 120 PSI, go to Step B. • If air flows from the supply line, replace the Air Filter Regulator. Go to Step C. • If air pressure is outside of range, repair vehicle air system as required. Repeat this step. • If air does not flow from the supply line, repair vehicle air supply to the regulator. Go to Step C. Purpose: Measure vehicle maintains air supply pressure. 1. Key off. 2. Monitor the vehicle air pressure gauge on the dash. • If vehicle maintains air pressure, go to Step C. • If vehicle loses air pressure, repair vehicle air system as required. Repeat this step. 150 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 E Fault Isolation Procedures | Fault Code 42 - Splitter Failed to Engage Purpose: Measure low splitter air pressures. F Purpose: Measure high splitter air pressures. 1. Key off. 1. Key on. 2. Start vehicle and allow air pressure to build to governor cut-off. 2. With Shift Control, select reverse (R2 in the gear display 13/18-speed). 3. Turn off engine, but leave key in on position. 4. With Shift Control, select reverse (R1 in gear display for 13/18-speed), then select neutral. Note: Five minutes is allowed for checking the pressure after shifting the transmissions to neutral. Note: If R2 isn’t displayed the up arrow button needs to be pressed. LO split 0-100 PSI gauge HI split 0-100 PSI gauge LO split 0-100 PSI gauge HI split 0-100 PSI gauge • If High Splitter gauge is 55 to 65 PSI and Low Splitter gauge is 0 PSI, repair Mechanical Splitter system as required. Go to Step V. • If Low Splitter gauge is 55 to 65 PSI and high Splitter gauge is 0 PSI, go to Step F. • If air pressure gauges do not read as shown above, replace the Splitter Valve. Go to Step V. • If air pressure gauges do not read as shown above, replace the Splitter Valve. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 151 Fault Code 42 - Splitter Failed to Engage | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Remove all pressure gauges. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 42 appears go to Step A. to find error in testing. • If fault code other than 42 appears, See “Fault Code Isolation Procedure Index” on page 8. 152 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 42 - Splitter Failed to Engage © 2016 Eaton. All rights reserved 153 Fault Code 43 - Range Solenoid Valve | Fault Isolation Procedures TRTS0930 Fault Code 43 - Range Solenoid Valve J1587: MID 130 J1939: SA 3 PID 35, 36 FMI 3, 4, 5 SPN 768, 769 FMI 3, 4, 5 Overview This fault code indicates an electrical failure of the solenoids that control the Range Solenoid Valve. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures this circuit. A failure mode of short to battery, short to ground or open circuit is detected. Fallback This fault causes a current range fallback and the transmission stays in either low range or high range. When the vehicle comes to a stop, an attempt to shift into low range is made. Possible Causes This fault code can be caused by any of the following: 154 • Range Solenoid Valve • Transmission Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 43 - Range Solenoid Valve Component Identification Range valve Transmission controller Transmission harness Range Alternate View - Combination Cylinder Models 2016.01.15 © 2016 Eaton. All rights reserved 155 TRTS0930 Fault Code 43 - Range Solenoid Valve | Fault Isolation Procedures Fault Code 43 - Range Solenoid Valve A Purpose: Measure resistance of high and low range solenoids through the Transmission Harness. B Purpose: Test the Range Solenoid Valve common line for shorts to ground through the Transmission Harness. 1. Key off. 1. Measure resistance between the Transmission Harness 38-way connector Pin 6 and ground. 2. Disconnect negative battery cable. 3. Disconnect the TECU 38-way connector. 4. Measure resistance between Pin 28 and Pin 6 and between Pin 34 and Pin 6 on the Transmission Harness 38-way connector. Front View Transmission ECU Connector 29 37 13 Note: Observe polarity on Volt\Ohm Meter. 14 35 31 32 23 24 25 26 27 28 15 30 16 17 18 33 19 20 7 8 9 10 11 12 1 2 3 4 5 6 OHMS 34 38 21 22 V COM A 36 Transmission Harness 38-way Connector • If resistance is 9 to 16 ohms, go to Step B. • If resistance is outside of range, go to Step C. • If resistance is OL, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If resistance is less than 10K ohm, go to Step C. 156 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 43 - Range Solenoid Valve Purpose: Measure resistance of high and low range solenoids at the Range Solenoid Valve. 1. Disconnect the Transmission Harness from Range Solenoid Valve. D Purpose: Test the Range Solenoid common line for shorts to ground at the Range Solenoid Valve. 1. Measure resistance between Range Solenoid Valve Pin C and ground. 2. Measure resistance between Pin A and Pin C and between Pin B and Pin C on the Range Solenoid Valve pins: OHMS C B A V C B A OHMS V COM C A B A V COM A A • If resistance is 9 to 16 ohms, go to Step D. • If resistance is outside of range, replace the Range Valve. Go to Step V. 2016.01.15 COM OHMS © 2016 Eaton. All rights reserved • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, replace the Range Valve. Go to Step V. 157 Fault Code 43 - Range Solenoid Valve | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 43 appears go to Step A. to find error in testing. • If code other than 43 appears, See “Fault Code Isolation Procedure Index” on page 8. 158 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 43 - Range Solenoid Valve © 2016 Eaton. All rights reserved 159 Fault Code 44 - Inertia Brake Solenoid Coil | Fault Isolation Procedures TRTS0930 Fault Code 44 - Inertia Brake Solenoid Coil J1587: MID 130 J1939: SA 3 SID 54 SPN 787 FMI 3, 4, 5 FMI 3, 4, 5 Overview This fault code indicates an electrical failure of the solenoid that controls the Inertia Brake. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures this circuit. A failure mode of a short to battery, short to ground or open circuit is detected. Fallback No Fallback Mode; however, if the Inertia Brake system failed, it may be difficult to engage a gear from a stop if the Inertia Brake was providing assistance (due to a dragging clutch). Also, hill shifting performance may be reduced. Possible Causes This fault code can be caused by any of the following: 160 • Inertia Brake Solenoid • Transmission Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 44 - Inertia Brake Solenoid Coil Component Identification Transmission controller Transmission harness Inertia brake solenoid coil 2016.01.15 © 2016 Eaton. All rights reserved 161 TRTS0930 Fault Code 44 - Inertia Brake Solenoid Coil | Fault Isolation Procedures Fault Code 44 - Inertia Brake Solenoid Coil A Purpose: Measure resistance of the Inertia Brake Solenoid coil through the Transmission Harness. 1. Key off. B Purpose: Test the high side solenoid coil for shorts to ground through the Transmission Harness. 1. Measure resistance between the Transmission Harness 38-way connector Pin 33 and ground. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. OHMS Front View 38-Way Connector 4. Measure resistance between the Transmission Harness 38-way connector Pin 33 and Pin 5. V 37 13 14 35 Transmission Harness 38-way Connector OHMS Front View 38-Way Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 Transmission Harness 38-way Connector • If resistance is 2 to 6 ohms, go to Step B. • If resistance is outside of range, go to Step C. 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 • If resistance is OL, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If resistance is less than 10K ohm, go to Step C. 162 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 44 - Inertia Brake Solenoid Coil Purpose: Measure resistance of the Inertia Brake Solenoid coil at the Inertia Brake. 1. Disconnect the Transmission Harness from Inertia Brake coil. D Purpose: Test the solenoid coil for shorts to ground at the Inertia Brake. 1. Measure resistance between Inertia Brake coil Pin A and ground. 2. Measure resistance between Inertia Brake coil Pin A and Pin B. OHMS A B V COM A OHMS A GROUND B V COM A • If resistance is 2 to 6 ohms, go to Step D. • If resistance is outside of range, replace the: - Medium-Duty Inertia Brake - Heavy-Duty Inertia Brake Go to Step V. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, replace the: - Medium-Duty Inertia Brake - Heavy-Duty Inertia Brake Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 163 Fault Code 44 - Inertia Brake Solenoid Coil | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, Test complete. • If Fault Code 44 appears go to Step A. to find error in testing. • If code other than 44 appears, See “Fault Code Isolation Procedure Index” on page 8. 164 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 44 - Inertia Brake Solenoid Coil © 2016 Eaton. All rights reserved 165 Fault Code 45 - High Capacity (HCIB) Failure | Fault Isolation Procedures TRTS0930 Fault Code 45 - High Capacity (HCIB) Failure J1587: MID 130 J1939: SA 3 SID 54 SPN 787 FMI 7 FMI 7 Overview The fault code indicates that the High Capacity Inertia Brake (HCIB) is not performing as expected. Detection The HCIB fault sets if the Inertia Brake is unable to synchronize the transmission during an upshift. Fallback No Fallback Mode; however, if the Inertia Brake system has failed, it may be difficult to engage a gear from a neutral and shifting performance may be reduced. Possible Causes This fault code can be caused by any of the following: • 166 Failed HCIB © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 45 - High Capacity (HCIB) Failure Component Identification Engine ECM Engine control system High Capacity Inertia brake A B 2016.01.15 © 2016 Eaton. All rights reserved 167 TRTS0930 Fault Code 45 - High Capacity (HCIB) Failure | Fault Isolation Procedures Fault Code 45 - High Capacity (HCIB) Failure A Purpose: Check for active or Inactive fault codes. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. Connect ServiceRanger. 2. Reconnect all connectors and verify that all components are properly installed. 3. Retrieve fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. • If Fault Code 27 or 44 are Active or Inactive, see the “Fault Code Isolation Procedure Index” on page 8 • If Fault Code 45 is Active or Inactive, go to Step B. 3. Key on. 4. Clear codes, See “Fault Code Retrieval/Clearing” on page 5. 5. Drive vehicle and verify proper transmission operation. Attempt to reset the code. 6. Check for fault codes, See “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 45 appears go to Step A. to find error in testing. B • If code other than 45 appears, See “Fault Code Isolation Procedure Index” on page 8. Purpose: Verify transmission model. 1. Verify transmission model. • If the transmission is an UltraShift model (DM3, LST, LEP, or AW3), Replace the: - Medium-Duty Inertia Brake - Heavy-Duty Inertia Brake Go to Step V. 168 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 45 - High Capacity (HCIB) Failure © 2016 Eaton. All rights reserved 169 Fault Code 46 - Splitter Direct and Indirect Solenoid Valve | Fault Isolation Procedures TRTS0930 Fault Code 46 - Splitter Direct and Indirect Solenoid Valve J1587: MID 130 J1939: SA 3 SID 37, 38 FMI 3, 4, 5 SPN 770, 771 FMI 3, 4, 5 Overview This fault code indicates an electrical failure of the solenoids that control the Splitter Solenoid Valve. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection Starting at key-on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures this circuit. Depending on the reading, a failure mode of short to battery, short to ground or open circuit is detected. Fallback This fault causes a current splitter fallback and the transmission stays in either low split or high split. Possible Causes This fault code can be caused by any of the following: 170 • Splitter Solenoid Valve • Transmission Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 46 - Splitter Direct and Indirect Solenoid Valve Component Identification Splitter valve Transmission controller Transmission harness Reduction Alternate View - Combination Cylinder Models 2016.01.15 © 2016 Eaton. All rights reserved 171 TRTS0930 Fault Code 46 - Splitter Direct Solenoid Valve | Fault Isolation Procedures Fault Code 46 - Splitter Direct Solenoid Valve A Purpose: Measure resistance of the high and low splitter solenoids through the Transmission Harness 1. Key off. B Purpose: Test the Splitter Solenoid Valve common line for shorts to ground through the Transmission Harness. 1. Measure resistance between the Transmission Harness 38-way connector Pin 4 and ground. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure resistance between the Transmission Harness 38-way connector pins: • 32 and 4 • 26 and 4 Front View 38-Way Connector OHMS 37 13 14 35 29 30 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 38 22 21 V COM A 36 Transmission Harness 38-way Connector • If resistance is OL, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Front View 38-Way Connector 23 17 Go to Step V. 23 17 • If resistance is less than 10K ohm, go to Step C. Transmission Harness 38-Way Connector • If resistance is 9 to 16 ohms, go to Step B. • If resistance is outside of range, go to Step C.. 172 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 46 - Splitter Direct Solenoid Valve Purpose: Measure resistance of the high and low splitter solenoids at the Splitter Solenoid Valve. D 1. Disconnect the Transmission Harness from Splitter Solenoid Valve. 1. Measure resistance between Splitter Solenoid Valve Pin C and ground. 2. Measure resistance between Splitter Solenoid Valve pins: - A and C - B and C C B A OHMS V COM C A B A OHMS C V COM B A V COM A GROUND OHMS A • If resistance is 9 to 16 ohms, go to Step D. • If resistance is outside of range, replace the Splitter Valve. Go to Step V. 2016.01.15 Purpose: Test the Splitter Solenoid Valve common line for shorts to ground. © 2016 Eaton. All rights reserved • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, replace the Splitter Valve and go to Step V. 173 Fault Code 46 - Splitter Direct Solenoid Valve | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the code. 6. Check for codes. See “Fault Code Retrieval/Clearing” on page 5. • If no codes, test complete. • If Fault Code 46 appears go to Step A. to find error in testing. • If code other than 46 appears, See “Fault Code Isolation Procedure Index” on page 8. 174 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 46 - Splitter Direct Solenoid Valve © 2016 Eaton. All rights reserved 175 TRTS0930 Fault Code 51 - Rail Position Sensor | Fault Isolation Procedures Fault Code 51 - Rail Position Sensor J1587: MID 130 J1939: SA 3 SID 60 SPN 60 FMI 2, 3, 4, 10 FMI 2, 3, 4, 10 Overview Fallback Mode During Operation This fault code indicates an electrical failure of the Rail Select Sensor or mechanical failure on the Electric Shifter. The transmission controller supplies sensor power to the Electric Shifter position sensors and uses the reported sensor position to determine gear finger location. There are 4 fault conditions defined by the reported FMI via ServiceRanger software. This fault will not be set if a System Battery Voltage Low fault (Fault Code 33) is active. • The transmission remains in its current gear. An F may appear in the gear display. • The service light will blink. • Until the fault is cleared, driver may have to shut off engine in gear. • Will not upshift, downshift nor shift into neutral. Conditions to Set Fault Code Inactive Detection • Starting at key-on and throughout operation, the transmission controller constantly monitors the position of the sensor. If a failure condition is detected, the fault code is set. FMI 2 - The fault becomes Inactive when the transmission controller detects the rail sensor output voltage is within 10% - 90% for 1 second or longer. • FMI 3, 4 - The fault becomes Inactive when the transmission controller detects the rail sensor supply is within +/- 5% of the expected voltage. • FMI 10 - The rail position is within + / - 0.093" (2%) of when the shift state went idle. Conditions to Set Fault Code Active • • FMI 2 - The transmission controller detects the rail sensor voltage is outside the 10-90% range for 1 second or longer. FMI 3 - The transmission controller detects the rail sensor supply voltage is 5% above the expected supply voltage for 1 second or longer. • FMI 4 - The transmission controller detects the rail sensor supply voltage is 5% below the expected supply voltage for 1 second or longer. • FMI 10 - The transmission controller detects the rail sensor signal moving more than +/- 0.093" (2%) when the rail motor is turned off in gear. Fallback This fault code can be caused by any of the following: FMI 2, 4, 10: • Transmission Harness - Connections and wires between the transmission controller and the rail sensor may be loose or damaged, terminals and wires may be bent, burnt or wires may be grounded, open or shorted. • Electric Shifter - The rail sensor may have been damaged or malfunctioned. FMI 3: Fallback mode During Power-Up 176 Possible Causes • • The transmission will power-up and may not be able to confirm neutral, no start gears can be selected. • Unit may not crank. An equal sign will appear in the display. © 2016 Eaton. All rights reserved Transmission Controller - The transmission controller may have been damaged or malfunctioned. 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 51 - Rail Position Sensor Component Identification Transmission Controller Front of Transmission OEM 18 19 20 10 11 12 A B C Gear select sensor A B C Front 36 38 Blue Connector Gen 3 Transmission Harness Assy K-3681 Rail select sensor XY Shifter Assy K-3784 35 37 Black Connector For Transmission Diagnostics 23 24 A B 15 16 (Located at the left rear corner of the transmission) 7 8 Output shaft speed sensor K-3231 A B A B Main shaft speed sensor K-3231 Input shaft speed sensor K-3231 B A C D 6 34 28 C B A 4 32 26 B C A C B A 17 31 25 Range valve K-3682 Splitter valve (13 & 18 speed only) K-3682 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 33 5 A B Inertia brake (Optional) 2016.01.15 © 2016 Eaton. All rights reserved 177 TRTS0930 Fault Code 51 - Rail Position Sensor | Fault Isolation Procedures Fault Code 51 - Rail Position Sensor A Purpose: Measure resistance of the Rail Position Sensors through the Transmission Harness. 1. If the fault code is Inactive put unit in PDM mode and perform the wire wiggle test. Check the overall harness connections to sensor. If a tone is heard and/or a fault code appears in the gear display, the Fault Code Isolation Procedure Index. B Purpose: Test the Rail Position Sensor Plus line for shorts to ground through the Transmission Harness. 1. Measure resistance between Transmission Harness 38-way connector Pin 18 to ground. 2. Key off. Front View 38-Way Connector 3. Disconnect negative battery cable. 37 4. Disconnect the Transmission Harness 38-way connector. 5. Measure resistance between Pin 18 and Pin 19 and between Pin 18 and Pin 20 on the Transmission Harness 38-way connector. Note: An Auto Ranging Digital Volt/Ohm Meter must be used. 6. Measure resistance of the Rail Position Sensors through the Transmission Harness. 37 13 14 35 29 30 31 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 32 10 11 12 1 2 3 4 5 6 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 V 38 21 COM A 22 36 13 14 35 38 V COM A 22 21 14 35 30 31 32 33 OHMS 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 V 38 COM A 22 21 36 Transmission Harness 38-way Connector • If resistance is OL, Reconnect 38-way connector, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If FMI 2, 3, 4, or 10 is present with an Inactive code, replace the Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If resistance is less than 10K ohm, go to Step C. OHMS 37 13 29 36 Transmission Harness 38-way Connector • If resistance between Pin 18 and Pin 19 is 100 to 200 ohms and between Pin 18 and Pin 20 resistance is 5K to 7K ohm, go to Step B. • If any of the above conditions are not met, go to Step C. 178 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 51 - Rail Position Sensor Purpose: Measure resistance of the Rail Position Sensor. 1. Disconnect Transmission Harness from Rail Select Sensor. D Purpose: Test the Rail Position Sensor Plus line for shorts to ground. 1. Measure resistance between Rail Select Sensor Pin A and ground. 2. Measure resistance between Pin A and Pin C and between Pin A and Pin B on the Rail Select Sensor. OHMS Note: An Auto Ranging Digital Volt/Ohm Meter must be used. V COM A C B A OHMS Ground OHMS V COM A V C C B B A A COM A • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance between Pin A and Pin C is 5K to 7K and between Pin A and Pin B is 100 to 200 ohms, go to Step D. • If resistance is less than 10K ohm, replace the Electric Shifter. Go to Step V. • If any of the above conditions are not met, replace the Electric Shifter. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 179 Fault Code 51 - Rail Position Sensor | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 51 appears go to Step A. to find error in testing. • If code other than 51 appears, See “Fault Code Isolation Procedure Index” on page 8. 180 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 51 - Rail Position Sensor © 2016 Eaton. All rights reserved 181 TRTS0930 Fault Code 52 - Gear Position Sensor | Fault Isolation Procedures Fault Code 52 - Gear Position Sensor J1587: MID 130 J1939: SA 3 SID 59 SPN 59 FMI 2, 3, 4, 7 FMI 2, 3, 4, 7 Overview Conditions to Set Fault Code Inactive This fault code indicates an electrical failure of the Rail Select Sensor or mechanical failure on the Electric Shifter. Conditions to Set the Fault Inactive The transmission controller supplies sensor power to the Electric Shifter position sensors and uses the reported sensor position to determine gear finger location. There are 4 fault conditions defined by the reported FMI via ServiceRanger software. This fault will not be set if a System Battery Voltage Low fault (Fault Code 33) is Active. • FMI 2 - The fault becomes Inactive when the transmission controller detects the gear sensor output voltage is within 10% - 90% for 1 second or longer. • FMI 3, 4 - The fault becomes Inactive when the transmission controller detects the gear sensor supply is within +/- 5% of the expected voltage. • FMI 7 - Shift finger is beyond maximum engagement. Detection Possible Causes Starting at key-on and throughout operation, the transmission controller constantly monitors the position of the sensor. If a failure condition is detected, the fault code is set. This fault code can be caused by any of the following: Conditions to Set Fault Code Active FMI 2, 4: • Transmission Harness - Connections and wires between the transmission controller and the rail sensor may be loose or damaged, terminals and wires may be bent, burnt or wires may be grounded, open, or shorted. • Electric Shifter - The rail sensor may have been damaged or malfunctioned. Conditions to Set the Fault Code Active • • • FMI 2 - The transmission controller detects the gear sensor voltage is outside the 10-90% range for 1 second or longer. FMI 3 - The transmission controller detects the gear sensor supply voltage is 5% above the expected supply voltage for 1 second or longer. FMI 4 - The transmission controller detects the gear sensor supply voltage is 5% below the expected supply voltage for 1 second or longer. FMI 3: • FMI 7: • Fallback Transmission Controller - The transmission controller may have been damaged or malfunctioned. Electric Shifter - Possible broken shift finger. Fallback mode During Power-Up • The transmission will power-up and may not be able to confirm neutral, no start gears can be selected. • Unit may not crank. An equal sign may appear in the display. Fallback Mode During Operation 182 • The transmission remains in its current gear. An F may appear in the gear display. • The service light will blink. • Until the fault is cleared, driver may have to shut off engine in gear. • Will not upshift, downshift nor shift to neutral. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 52 - Gear Position Sensor Component Identification Transmission Controller Front of Transmission OEM 18 19 20 10 11 12 A B C Gear select sensor B C A Front 36 38 Blue Connector Gen 3 Transmission Harness Assy K-3681 Rail select sensor XY Shifter Assy K-3784 35 37 Black Connector For Transmission Diagnostics 23 24 A B 15 16 (Located at the left rear corner of the transmission) 7 8 Output shaft speed sensor K-3231 A B A B Main shaft speed sensor K-3231 Input shaft speed sensor K-3231 B A C D 6 34 28 C B A 4 32 26 B C A C B A 17 31 25 Range valve K-3682 Splitter valve (13 & 18 speed only) K-3682 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 33 5 A B Inertia brake (Optional) 2016.01.15 © 2016 Eaton. All rights reserved 183 TRTS0930 Fault Code 52 - Gear Position Sensor | Fault Isolation Procedures Fault Code 52 - Gear Position Sensor A Purpose: Measure resistance of the Gear Position Sensor through the Transmission Harness 1. If the fault code is Inactive, see “Product Diagnostic (PD) Mode” on page 11. Perform the wire wiggle test. Check the overall harness connections to sensor. If a tone is heard and/or a fault code appears in the gear display, see “Fault Code Isolation Procedure Index” on page 8.. B Purpose: Test the Gear Position Sensor Plus line for shorts to ground through the Transmission Harness. 1. Measure resistance between Transmission Harness 38-way connector Pin 10 to ground. 2. Key off. Front View 38-Way Connector 3. Disconnect negative battery cable. 29 37 13 14 35 4. Disconnect the Transmission Harness 38-way connector. 5. Measure resistance between Transmission Harness 38-way connector pins: - 10 and 11 - 10 and 12 Note: An Auto Ranging Digital Volt/Ohm Meter must be used. • If resistance between Pin 10 and Pin 11 is 100 to 200 ohms and between Pin 10 and Pin 12 is 5K to 7K ohm, go to Step B. • If any of the above conditions are not met, go to Step C. 30 OHMS 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 V 38 COM A 22 21 36 Transmission Harness 38-way Connector • If resistance is OL, reconnect 38-way connector, (if fault code is Active.) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) • If FMI 2, 3, or 4 is present with an Inactive code, replace the Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If FMI 7 is present, remove Electric Shifter to inspect for a broken shift finger. If the shift finger is broken, replace the Electric Shifter. • If resistance is less than 10K ohm, go to Step C. 184 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 52 - Gear Position Sensor Purpose: Measure resistance of the Gear Position Sensor. 1. Disconnect Transmission Harness from Gear Select Sensor. D Purpose: Test the Gear Position Sensor Plus line for shorts to ground. 1. Measure resistance between Gear Select Sensor Pin A and ground. 2. Measure resistance between Gear Select Sensor pins: - A and C - A and B OHMS V COM A C Note: An Auto Ranging Digital Volt/Ohm Meter must be used. B A Ground OHMS OHMS V COM A V C C B B A A COM A • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, replace Electric Shifter. Go to Step V. • If Pin A and Pin C resistance is 5K to 7K ohm and if Pin A and Pin B resistance is 100 to 200 ohms, go to Step D. • If any of the above conditions are not met, replace Electric Shifter. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 185 Fault Code 52 - Gear Position Sensor | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 52 appears, go to Step A. to find error in testing. • If code other than 52 appears, See “Fault Code Isolation Procedure Index” on page 8. 186 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 52 - Gear Position Sensor © 2016 Eaton. All rights reserved 187 Fault Code 56 - Input Shaft Speed Sensor | Fault Isolation Procedures TRTS0930 Fault Code 56 - Input Shaft Speed Sensor J1587: MID 130 J1939: SA 3 PID 161 SPN 161 FMI 2, 3, 4, 5, 10 FMI 2, 3, 4, 5, 10 Overview This fault code indicates an electrical problem in the Input Shaft Speed Sensor circuit. The signal from the sensor did not match the current operating conditions. When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection A speed sensor is determined faulty when all the speed sensor readings are compared and one sensor is inconsistent, or the sensor is shorted to power or ground. Fallback This fault causes an in-place fallback. If the Input Shaft Speed Sensor fails before power-up, the transmission is unable to engage a gear. Possible Causes This fault code can be caused by any of the following: 188 • Transmission Harness • Input Shaft Speed Sensor • Various Transmission Components • Transmission Electronic Control Unit (TECU) © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 56 - Input Shaft Speed Sensor Component Identification Input shaft speed sensor Transmission controller 2016.01.15 Transmission harness © 2016 Eaton. All rights reserved 189 TRTS0930 Fault Code 56 - Input Shaft Speed Sensor | Fault Isolation Procedures Fault Code 56 - Input Shaft Speed Sensor A Purpose: Monitor engine speed and Input Shaft speed in ServiceRanger. 1. Drive vehicle and monitor engine RPM and Input Shaft RPM with ServiceRanger. B Purpose: Measure Input Shaft Speed Sensor resistance and test for short through the Transmission Harness. 1. Key off. • If engine RPM and Input Shaft RPM are the same, and code is not active during test drive, test complete. 2. Disconnect negative battery cable. • If Input Shaft RPM is erratic or varies from engine RPM, go to Step B. 4. Measure resistance between the Transmission Harness 38-way connector pins: - 7 and 8 - 7 and ground 3. Disconnect the Transmission Harness 38-way connector. OHMS Front View 38-Way Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 29 30 33 COM A 38 21 22 36 OHMS 37 13 14 35 31 32 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 V COM A 22 21 36 Transmission Harness 38-way Connector • If resistance between Pin 7 and Pin 8 is 2K to 4.5K ohm and Pin 7 to ground is OL, go to Step C. • If resistance is outside of the range, go to Step D. 190 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 56 - Input Shaft Speed Sensor Purpose: Visually inspect Input Shaft Speed Sensor. 1. Inspect Input Shaft Speed Sensor for contamination or damage. E Purpose: Test Input Shaft Speed Sensor for shorts to ground. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. • If no problem found, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) OHMS A V COM B A GROUND Go to Step V. • If problem found or you were sent here from Step D or E, replace Input Shaft Speed Sensor and inspect the upper countershaft PTO gear for damage and go to Step V. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, go to Step C. D Purpose: Measure Input Shaft Speed Sensor resistance at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from Input Shaft Speed Sensor. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. OHMS A V COM B A • If resistance is 2K to 4.5K ohm, go to Step E. • If resistance is outside of range, go to Step C. 2016.01.15 © 2016 Eaton. All rights reserved 191 Fault Code 56 - Input Shaft Speed Sensor | Fault Isolation Procedures V TRTS0930 Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Verify proper installation of speed sensor. 4. Key on. 5. Clear fault codes. See “Fault Code Retrieval/Clearing” on page 5. 6. Drive the vehicle and attempt to reset the fault code. 7. Check for fault codes. See “Fault Code Retrieval/Clearing” on page 5. • If no fault code, test complete. • If Fault Code 56 appears, go to Step A. to find error in testing, • If fault code other than 56 appears, See “Fault Code Isolation Procedure Index” on page 8. 192 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 56 - Input Shaft Speed Sensor © 2016 Eaton. All rights reserved 193 Fault Code 57 - Main Shaft Speed Sensor | Fault Isolation Procedures TRTS0930 Fault Code 57 - Main Shaft Speed Sensor J1587: MID 130 J1939: SA 3 PID 160 SPN 160 FMI 2, 3, 4, 5 FMI 2, 3, 4, 5 Overview This fault code indicates an electrical problem in the Main Shaft Speed Sensor circuit. The signal from the sensor did not match the current operating conditions When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection A speed sensor is determined faulty when all the speed sensor readings are compared and one sensor is inconsistent, or the sensor is shorted to power or ground. Fallback This fault causes an In-Place fallback mode. Possible Causes This fault code can be caused by any of the following: 194 • Transmission Harness • Main Shaft Speed Sensor • Various transmission components • Transmission Electronic Control Unit (TECU) © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 57 - Main Shaft Speed Sensor Component Identification Transmission controller 2016.01.15 Main shaft speed sensor Transmission harness © 2016 Eaton. All rights reserved 195 TRTS0930 Fault Code 57 - Main Shaft Speed Sensor | Fault Isolation Procedures Fault Code 57 - Main Shaft Speed Sensor A Purpose: Measure Main Shaft Speed Sensor resistance, test for short to ground through the Transmission Harness C Purpose: Measure Main Shaft Speed Sensor resistance. 1. Disconnect the Transmission Harness from the Main Shaft Speed Sensor. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector 2. Measure resistance between the Main Shaft Speed Sensor Pin A and Pin B. 4. Measure resistance between the Transmission Harness 38-way connector pins: - 15 and 16 - 15 and ground • If resistance between Pin 15 and Pin 16 is 2k to 4.5K ohm and between Pin 15 to ground is OL, go to Step B. OHMS A V COM B A • If resistance is 2K to 4.5K ohm, go to Step D. • If resistance is outside of range, go to Step B. • If resistance is outside of the range, go to Step C. B Purpose: Visually inspect the Main Shaft Speed Sensor for contamination and damage. 1. Inspect Main Shaft Speed Sensor for contamination or damage. • If no problem found, replace TECU (only if fault code is Active) and go to Step V. • If problem is found or you were sent here from Step C or D, replace Main Shaft Speed Sensor and inspect the upper reverse idler gear for damage and go to Step V. 196 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Fault Isolation Procedures | Fault Code 57 - Main Shaft Speed Sensor Purpose: Test Main Shaft Speed Sensor for shorts to ground. 1. Measure resistance between Main Shaft Speed Sensor Pin A and ground. OHMS A V COM V Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Verify proper installation of speed sensor. B 4. Key on. A 5. Clear codes. See “Fault Code Retrieval/Clearing” on page 5. GROUND • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness 6. Drive the vehicle and attempt to reset the fault code. 7. Check for fault codes. See “Fault Code Retrieval/Clearing” on page 5. Go to Step V. • If no fault codes, test complete. • If resistance is less than 10K ohm, go to Step B. • If Fault Code 57 appears, find error in testing go to Step A. • If fault code other than 57 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 197 Fault Code 58 - Output Shaft Speed Sensor | Fault Isolation Procedures TRTS0930 Fault Code 58 - Output Shaft Speed Sensor J1587: MID 130 J1939: SA 3 PID 191 SPN 191 FMI 2, 3, 4, 5, 6, 8 FMI 2, 3, 4, 5, 6, 8 Overview This fault code indicates an electrical problem in the Output Shaft Speed Sensor circuit. The signal from the sensor did not match the current operating conditions When troubleshooting an Inactive code See “Product Diagnostic (PD) Mode” on page 11. Detection A speed sensor is determined faulty when all the speed sensor readings are compared and one sensor is inconsistent, the sensor is shorted to power or ground, a grounded circuit is detected, or if an abnormal frequency is detected. Fallback This fault causes an In-Place fallback. Possible Causes This fault code can be caused by any of the following: 198 • Transmission Harness • Output Shaft Speed Sensor • Various transmission components • Transmission Electronic Control Unit (TECU) • Failed or loose Tone Wheel © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 58 - Output Shaft Speed Sensor Component Identification Transmission controller 2016.01.15 Transmission harness © 2016 Eaton. All rights reserved Output shaft speed sensor 199 TRTS0930 Fault Code 58 - Output Shaft Speed Sensor | Fault Isolation Procedures Fault Code 58 - Output Shaft Speed Sensor A Purpose: Measure Output Shaft Speed Sensor resistance and test for short to ground through Transmission Harness. B 1. Inspect Output Shaft Speed Sensor for contamination or damage. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure resistance between the Transmission Harness 38-way connector pins: - 23 and 24 - 23 and ground 200 Purpose: Visually inspect Output Shaft Speed sensor for contamination and damage. • If no problem found, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) go to Step V. • If resistance between Pin 23 and Pin 24 is 2K to 4.5K ohm and between Pin 23 to ground is OL, go to Step B. • If problem is found or you were sent here from Step C or D, replace the: - Medium-Duty Output Shaft Speed Sensor - Heavy-Duty Output Shaft Speed Sensor • If resistance is outside of the range, go to Step C. Inspect the tone wheel for damage, looseness or corrosion. Go to Step V. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 58 - Output Shaft Speed Sensor Purpose: Measure Output Shaft Speed Sensor resistance. 1. Disconnect the Transmission Harness from the Output Shaft Speed Sensor. 2. Measure resistance between Output Shaft Speed Sensor Pin A and Pin B. OHMS COM Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Verify proper installation of speed sensor. 4. Key on. B A V V 5. Clear fault codes. A 6. Drive the vehicle and attempt to reset the fault code. 7. Check for fault codes. • If resistance is 2K to 4.5K ohm, go to Step D. • If no fault codes, test complete. • If resistance is outside of range, go to Step B. • If Fault Code 58 appears go to Step A. to find error in testing. • If fault code other than 58 appears, See “Fault Code Isolation Procedure Index” on page 8. D Purpose: Test for shorts to ground of the Output Shaft Speed sensor. 1. Measure resistance between Output Shaft Speed Sensor Pin A and ground. OHMS A V COM B A GROUND • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, go to Step B. 2016.01.15 © 2016 Eaton. All rights reserved 201 TRTS0930 Fault Code 61 - Rail Select Motor | Fault Isolation Procedures Fault Code 61 - Rail Select Motor J1587: MID 130 J1939: SA 3 SID 39 SPN 772 FMI 1, 5, 6, 12 FMI 1, 5, 6, 12 Overview Fallback Mode During Operation This fault indicates the Electric Shifter Rail Motor system is not working properly. The Transmission Electronic Control Unit (TECU) checks the rail motor for open or shorted connections. There are four fault conditions defined by the reported FMI via ServiceRanger software. • The transmission remains in its current gear. An F may appear in the gear display. • The service light will blink. • Until the fault is cleared, driver may have to shut off engine in gear. Conditions to Set Fault Code Inactive Detection Starting at key-on and throughout operation, the TECU constantly monitors the motor circuit. If a failure mode of short to battery, short to ground, open circuit, or low current is detected the fault is set. Conditions to Set the Fault Code Inactive • FMI 1, 12 - The fault becomes Inactive when the shift is completed. • FMI 5, 6 - The fault becomes Inactive when the open or short circuit conditions are not detected for 0.5 seconds. Conditions to Set Fault Code Active Conditions to Set the Fault Code Active • • • FMI 1 - The TECU detects a high resistance in the motor circuit (5 ohms or greater) resulting in slow or no movement of the XY Shift finger. This fault will set when the Electric Shifter fails to select the proper rail. FMI 5, 6 - This fault is set when the condition is detected for at least 0.5 seconds and the TECU attempts to move the XY shift finger. FMI 5 is open or shorted to ground, FMI 6 is shorted to power. FMI 12 - The TECU detects a fault condition within the TECU XY control circuit, resulting in slow or no movement of the XY shift finger. This fault is set when the Electric Shifter fails to select the proper rail. Fallback Fallback Mode During Power-Up • • 202 The transmission will power-up and may not be able to confirm neutral, no start gear can be selected. The engine will not crank and a dash will be shown in the gear display. Possible Causes This fault code can be caused by any of the following: FMI 1, 5: • The Electric Shifter rail motor may be damaged, failed or has developed a low resistance to ground. • Connections and wires between the rail motor and the TECU may be loose or damaged, terminals and wires may be bent, or terminals may be burnt. • TECU may have an internal short to ground or open circuit and has failed. FMI 6: • The wires between the rail motor and the TECU may be grounded or shorted. • TECU may have internal short to power and has failed. FMI 12: • Poor chassis power or ground. • The wires between the rail motor and the TECU may be grounded or shorted. • TECU internal failure. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 61 - Rail Select Motor Component Identification Transmission Controller Front of Transmission OEM 18 19 20 10 11 12 A B C Gear select sensor B C A Front 36 38 Blue Connector Transmission Harness Assy Rail select sensor XY Shifter Assy 35 37 Black Connector For Transmission Diagnostics 23 24 A B 15 16 (Located at the left rear corner of the transmission) 7 8 Output shaft speed sensor A B A B Main shaft speed sensor Input shaft speed sensor B A C D 6 34 28 C B A 4 32 26 B C A C B A Range valve Splitter valve (13 & 18 speed only) 17 31 25 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 33 5 A B Inertia brake (Optional) 2016.01.15 © 2016 Eaton. All rights reserved 203 TRTS0930 Fault Code 61 - Rail Select Motor | Fault Isolation Procedures Fault Code 61 - Rail Select Motor A Purpose: Check for active or Inactive fault codes (noting FMI) and perform electrical pretest. 1. Use ServiceRanger to retrieve and record fault code 61 FMI information. 2. Perform the “Electrical Pretest” on page 12, inspect TECU power supply harness and fuse holder. • Issue found with TECU power supply harness or vehicle batteries, repair or replace items found during electrical pretest, go to Step V. B Purpose: Measure the resistance of Electric Shifter Rail motor through the Transmission Harness. 1. Key off. 2. Disconnect the negative battery cable. 3. Disconnect the Transmission Harness 38-way connector from the TECU. 4. Measure resistance between Pin 35 and Pin 37. • Electrical pretest passed, no issues found, go to Step B. OHMS Front View 38-Way Connector V COM A 29 37 13 14 35 33 34 23 24 25 26 27 28 15 30 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 38 21 22 36 Transmission Harness 38-way Connector • Measured resistance is 2 ohms or less, go to Step C. • Measured resistance is greater than 2 ohms, go to Step D. 204 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 61 - Rail Select Motor Purpose: Test the Electric Shifter Rail Motor for short to ground through the Transmission Harness. D 1. Measure the resistance between Pin 35 and ground. 1. Disconnect the black 2-way rail motor connector from the transmission harness. 2. Measure the resistance of the Rail Motor at the 2-way connector. - Pin A to Pin B - Pin A to Ground OHMS Front View 38-Way Connector V COM A 29 37 13 14 35 30 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 Purpose: Measure the resistance of Electric Shifter Rail motor at the Rail Motor and test for short to ground. 38 21 22 36 Transmission Harness 38-way Connector OHMS OHMS B B A • Measured resistance is 1 M ohm or greater, go to Step E. A V V COM COM A A • Measured resistance is less than 1 M ohm, go to Step D. • Measured resistance between Pin A and Pin B is 2 ohms or less, and Pin A to ground is 1 M ohm or greater, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • Measured resistance is out of range, replace the Electric Shifter. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 205 TRTS0930 Fault Code 61 - Rail Select Motor | Fault Isolation Procedures E Purpose: Use fault code FMI to make a repair decision. Go to Step V. Date Code: Model: Hardware Rev: Serialno: 1. FMI information recorded from Step A. • FMI 6 or 12 is Active or Inactive, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) TECU Serial Number • FMI 1 or 5 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • FMI 1 or 5 is Inactive and the TECU serial number is between ETC2000000 and ETC2029918, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • FMI 1 or 5 is Inactive and the TECU serial number is above ETC2029918, replace the Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. 206 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 61 - Rail Select Motor Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 61 appears, find error in testing, go to Step A. 2016.01.15 © 2016 Eaton. All rights reserved 207 TRTS0930 Fault Code 63 - Gear Select Motor | Fault Isolation Procedures Fault Code 63 - Gear Select Motor J1587: MID 130 J1939: SA 3 SID 40 SPN 773 FMI 1, 5, 6, 12 FMI 1, 5, 6, 12 Overview Fallback Mode During Operation This fault indicates the Electric Shifter Gear Motor system is not working properly. The Transmission Electronic Control Unit (TECU) checks the gear motor and controller for open or shorted connections. There are 4 fault conditions defined by the reported FMI via ServiceRanger software. • The transmission remains in its current gear. An F may appear in the gear display. • The service light will blink. • Until the fault is cleared, driver may have to shut off engine in gear. Conditions to Set Fault Code Inactive Detection Starting at key-on and throughout operation, the TECU constantly monitors the motor circuit. If a failure mode of short to battery, short to ground, open circuit or low current is detected the fault is set. Conditions to Set the Fault Inactive • FMI 1, 12 - The fault becomes Inactive when the shift is completed. • FMI 5, 6 - The fault becomes Inactive when the open or short circuit conditions are not detected for 0.5 seconds. Conditions to Set Fault Code Active Conditions to Set the Fault Code Active • • • FMI 1 - The TECU detects a high resistance in the motor circuit (5 ohms or greater) resulting in slow or no movement of the XY shift finger. This fault will set when the Electric Shifter fails to engage or disengage a gear. FMI 5, 6 - This fault is set when the condition is detected for at least 0.5 seconds and the TECU attempts to move the XY shift finger. FMI 5 is open or shorted to ground, FMI 6 is shorted to power. FMI 12 - The TECU detects a fault condition within the TECU XY control circuit, resulting in slow or no movement of the XY shift finger. This fault is set when the Electric Shifter fails to engage or disengage a gear. Fallback Fallback Mode During Power-Up • • 208 The transmission will power-up and may not be able to confirm neutral, no start gear can be selected. The engine will not crank and a dash will be shown in the gear display. Possible Causes This fault code can be caused by any of the following: FMI 1, 5: • The Electric Shifter gear motor may be damaged, failed, or has developed a low resistance to ground. • Connections and wires between the gear motor and the TECU may be loose or damaged, terminals and wires may be bent or terminals may be burnt. • TECU may have an internal short to ground or open circuit and has failed. FMI 6: • The wires between the gear motor and TECU may be shorted to power. • TECU may have internal short to power and has failed. FMI 12: • Poor chassis power or ground. • The wires between the gear motor and TECU may be shorted to ground. • TECU internal failure. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 63 - Gear Select Motor Component Identification Transmission Controller Front of Transmission OEM 18 19 20 10 11 12 A B C Gear select sensor B C A Front 36 38 Blue Connector Transmission Harness Assy Rail select sensor XY Shifter Assy 35 37 Black Connector For Transmission Diagnostics 23 24 A B 15 16 (Located at the left rear corner of the transmission) 7 8 Output shaft speed sensor A B A B Main shaft speed sensor Input shaft speed sensor B A C D 6 34 28 C B A 4 32 26 B C A C B A Range valve Splitter valve (13 & 18 speed only) 17 31 25 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 33 5 A B Inertia brake (Optional) 2016.01.15 © 2016 Eaton. All rights reserved 209 TRTS0930 Fault Code 63 - Gear Select Motor | Fault Isolation Procedures Fault Code 63 - Gear Select Motor A Purpose: Check for active or Inactive fault codes (noting FMI) and perform electrical pretest. 1. Use ServiceRanger to retrieve and record Fault Code 63 FMI information. 2. Perform electrical pretest, see “Electrical Pretest” on page 12. Inspect TECU power supply harness and fuse holder. • If issue found with TECU power supply harness or vehicle batteries, repair or replace items found during electrical pretest. go to Step V. B Purpose: Measure the resistance of Electric Shifter Gear Motor through the Transmission Harness. 1. Key off. 2. Disconnect the negative battery cable. 3. Disconnect the Transmission Harness 38-way connector from the TECU. 4. Measure resistance between Pin 36 and Pin 38. OHMS Front View 38-Way Connector • Electrical pretest passed, no issues found, go to Step B. V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 Transmission Harness 38-way Connector • Measured resistance is 2 ohms or less, go to Step C. • Measured resistance is greater than 2 ohms, go to Step D. 210 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 63 - Gear Select Motor Purpose: Test the Electric Shifter for a short to ground through the Transmission Harness. 1. Measure the resistance between Pin 36 and ground. 1. Disconnect the blue 2-way gear motor connector from the transmission harness. OHMS Front View 38-Way Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM Purpose: Measure the resistance of the Electric Shifter Gear Motor, and test for short to ground. D A 2. Measure the resistance of the gear motor at the 2-way connector. - Pin A to Pin B - Pin A to Ground 38 22 21 36 Transmission Harness 38-way Connector OHMS OHMS • If measured resistance is 1 M ohm or greater, go to Step E. B B A A V V COM COM A A • If measured resistance is less than 1 M ohm, go to Step D. • If measured resistance between Pin A and Pin B is 2 ohms or less, and between Pin A and ground is 1 M ohm or greater, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If measured resistance is out of range, replace the Electric Shifter. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 211 TRTS0930 Fault Code 63 - Gear Select Motor | Fault Isolation Procedures E Purpose: Use the fault code FMI to make a repair decision. go to Step V. Date Code: Model: Hardware Rev: Serialno: 1. FMI information recorded from Step A. • If FMI 6 or 12 is active or Inactive, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) TECU Serial Number • If FMI 1 or 5 is Active, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If FMI 1 or 5 is Inactive and the TECU serial number is between ETC2000000 and ETC2029918, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If FMI 1 or 5 is Inactive and the TECU serial number is above ETC2029918, replace the Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. 212 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 63 - Gear Select Motor Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 63 appears go to Step A. to find error in testing. • If fault code other than 63 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 213 Fault Code 68 - Grade Sensor | Fault Isolation Procedures TRTS0930 Fault Code 68 - Grade Sensor J1587: MID 130 J1939: SA 3 SID 227 FMI 14 SPN 520274, 520321FMI 13, 14 Overview The Grade Sensor is mounted inside the Transmission Electronic Control Unit (TECU) and is essential for Hill-Start Aid. The Grade Sensor also provides information to the TECU to assist in smooth vehicle launch and shifting. Detection A fault will be set if the grade sensor reports an illogical grade to the TECU. Fallback Hill-Start-Aid is enabled all the time. Possible Causes This fault code can be caused by any of the following: 214 • Improperly mounted TECU • Uncalibrated TECU • TECU failure © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 68 - Grade Sensor Component Identification Transmission ECU 2016.01.15 © 2016 Eaton. All rights reserved 215 TRTS0930 Fault Code 68 - Grade Sensor | Fault Isolation Procedures Fault Code 68 - Grade Sensor A Purpose: Check for active and Inactive fault codes (noting FMI) and perform electrical pretest. 1. Key on. 2. Retrieve active fault codes and FMIs with ServiceRanger using the 9-way diagnostic connector. 3. Perform electrical pretest, See “Electrical Pretest” on page 12. • If FMI 13 is Active after performing the electrical pretest, go to Step B. B Note: Before Grade Sensor Calibration, verify the vehicle is on level ground, the suspension is fully aired and the vehicle is at the appropriate ride height. 1. Key on. 2. Calibrate the TECU using ServiceRanger. (steps below) Note: The Grade Sensor can be calibrated via ServiceRanger or operator-triggered Special Function. Detailed instructions on both methods can be found in service manual TRSM0930. • If FMI 14 is Active after performing the electrical pretest, go to Step C. • If issue was repair during the electrical pretest, go to Step V. Purpose: Perform TECU Grade Sensor calibration. 3. Open the Advanced Product Functions menu and click on the transmission model. 4. Open the Grade Sensor Calibration and follow the instructions. 5. Click on Calibrate Grade Sensor. 6. Verify Fault Code 68 has gone Inactive. • If FMI 13 is not Active, Close ServiceRanger and turn off ignition switch to save calibration. go to Step V. • If FMI 13 is still Active, call Roadranger Tech Support at 1-800-826-4357 for assistance. 216 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 68 - Grade Sensor Purpose: Confirm proper TECU mounting. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. Ensure that the TECU is properly mounted and secured. 2. Reconnect all connectors. • If TECU found insecure or not properly mounted, properly secure the TECU. Go to Step V. • If TECU was found properly mounted and secure, (if fault code is Active) replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) 3. Key on. 4. Clear codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. Go to Step V. • If no fault codes, Test complete. • If Fault Code 68 appears go to Step A. to find error in testing. • If fault code other than 68 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 217 TRTS0930 Fault Code 71 - Unable to Disengage Gear | Fault Isolation Procedures Fault Code 71 - Unable to Disengage Gear J1587: MID 130 J1939: SA 3 SID 60 SPN 560 FMI 7 FMI 7 Overview Possible Causes This fault indicates the system cannot disengage from the current gear. The system will continue attempting to disengage the current gear after the fault is set. This fault code can be caused by any of the following: Vehicle must be moving and attempting to change gear position and no electrical faults are active. The system is unable to select the neutral position after 3 consecutive attempts. Conditions to Set Fault Code Active Conditions to Set the Fault Code Active FMI 7 - The system is unable to select the neutral position after 3 consecutive attempts. Fallback Fallback mode During Power-Up • • Mechanical issue with the shift bar housing • Damaged shift bar housing interlock parts Electric Shifter Detection • Shift Bar Housing None. This fault can not be set at power-up. • New Electric Shifter installed and not recalibrated per the L-Letter (L-2003-30) • Mechanical issue with the Electric Shifter • Badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leak • Worn center shaft bushing (TAIB-0814.) Base Transmission • Main box mechanical failure • Sliding clutch / shift yoke wear Transmission Electronic Control Unit (TECU) Fallback Mode During Operation • • When this fault is Active, the transmission will continue to attempt to select neutral. • The system will alternate the engine speed up and down in an attempt to achieve disengagement. • The gear display may blink the destination gear. • The service light will not flash, nor will an F be displayed on the dash. • The diagnostic code will not be transmitted on the J1587 bus until fault codes have been requested by a service tool. New TECU installed and not recalibrated per the L-Letter (L-2005-04) Engine • Inaccurately reporting engine torque value Conditions to Set Fault Code Inactive Conditions to Set the Fault Inactive • 218 FMI 7 - The fault becomes Inactive when neutral is achieved. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 71 - Unable to Disengage Gear Component Identification Shift bar housing Electric shifter Transmission controller Base Transmission Engine ECM Engine Torque Value 2016.01.15 © 2016 Eaton. All rights reserved 219 TRTS0930 Fault Code 71 - Unable to Disengage Gear | Fault Isolation Procedures Fault Code 71 - Unable to Disengage Gear A Purpose: Determine if an Electric Shifter was installed without recalibrating the transmission. B Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse, power and ground supplies to the TECU. 1. Key off. 2. Was a new Electric Shifter or TECU just installed without recalibrating the transmission? • Yes, perform transmission calibration. Turn key on, and allow the transmission to power up. Turn key off, wait 2 minutes and go to Step V.. 1. Key off. 2. Inspect starter, battery and in-line fuse holder connections for integrity. 3. Measure voltage across batteries. Front of Transmission Transmission ECU • No, go to Step B. VOLTS V COM – + – + A Transmission Harness OEM Harness 36 38 Battery power (Non-switched power) run to starter or Battery 30 AMP fuse – – + + • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required and go to Step C. • If voltage is outside of range, repair or replace batteries and charge system as required. Repeat test. 220 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 71 - Unable to Disengage Gear Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate the diagnostic port on the Transmission Harness - located at the left rear corner of the transmission. D Purpose: Measure batter voltage at 4-way diagnostic port. 1. Key on. 2. Measure voltage between Pin B and Pin C. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. 4-Pin Diagnostics Port VOLTS V B A C D COM A 4-Pin Diagnostics Port B A C D 4-way Battery Negative Post B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step E. 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage between Pin C and battery negative post is 0.70 volts or less, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 © 2016 Eaton. All rights reserved 221 TRTS0930 Fault Code 71 - Unable to Disengage Gear | Fault Isolation Procedures E Purpose: Measure ignition voltage at 4-way diagnostic port. F Purpose: Visually inspect the Shift bar housing, Electric Shifter and base transmission for signs of mechanical damage. 1. Key on. 1. Key off. 2. Measure voltage between Pin A and Pin C. 2. Remove electric shifter from Shift Bar Housing. 3. Inspect the Shift Bar Housing - Visually inspect shift rails and blocks. - Verify shift bar housing operation by confirming shift rails can physically engage each gear individually. - Confirm the shift bar housing can not engage 2 gears at the same time. 4-Pin Diagnostics Port B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step F. • If voltage is outside of range, repair Ignition power supply to TECU. Fuse may be blown. Repeat test. 4. Inspect Electric Shifter - Check for mechanical issues with the Electric Shifter. - Visually inspect for badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leaks. - Check for a worn center shaft bushing (see TAIB-0814). 5. Inspect Base Transmission - Drain and inspect oil for debris. - Remove I-brake or PTO cover and inspect for main box mechanical failure. - Inspect sliding clutches and shift yokes for wear. • If no problem found, replace Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If problem found, repair as required and go to Step V. 222 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 71 - Unable to Disengage Gear Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 71 appears go to Step A. to find error in testing. • If fault code other than 71 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 223 TRTS0930 Fault Code 72 - Failed to Select Rail | Fault Isolation Procedures Fault Code 72 - Failed to Select Rail J1587: MID 130 J1939: SA 3 SID 59 SPN 772 FMI 7 FMI 7 Overview Possible Causes This fault indicates the system is unable to position the XY shift finger on the desired shift rail. The system will continue attempting to select the desired rail position after the fault is set. This fault code can be caused by any of the following: Vehicle must be moving and attempting to select a rail and no electrical faults are active. FMI 7: • Mechanical issue with the shift bar housing • Damaged shift bar housing interlock parts Electric Shifter Detection • The system is unable to select the desired rail position after 5 consecutive attempts. New Electric Shifter installed and not recalibrated per the L-Letter (L-2003-30) • Mechanical issue with the Electric Shifter Conditions to Set Fault Code Active • Badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leak • Worn center shaft bushing (TAIB-0814) Conditions to Set the Fault Code Active • FMI 7 - The system is unable to select the desired rail position after five consecutive attempts. Fallback Fallback mode During Power-Up • Vehicle may not crank. A dash will appear in the gear display. Base Transmission • Main box mechanical failure • Sliding clutch / shift yoke wear Transmission Electronic Control Unit (TECU) • Fallback Mode During Operation • When this fault is active, the transmission will continue to attempt to select the desired rail position. • The system will alternate the engine speed up and down during a shift. • The gear display may blink the destination gear. • The service light will not flash, nor will an F be displayed on the dash. • The diagnostic code will not be transmitted on the J1587 bus until fault codes have been requested by a service tool. New TECU installed and not recalibrated per the L-Letter (L-2005-04) Conditions to Set Fault Code Inactive Conditions to Set the Fault Inactive • 224 FMI 7 - The fault becomes Inactive when the desired rail position is achieved. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 72 - Failed to Select Rail Component Identification Shift bar housing Electric shifter Transmission controller 2016.01.15 Base Transmission © 2016 Eaton. All rights reserved 225 TRTS0930 Fault Code 72 - Failed to Select Rail | Fault Isolation Procedures Fault Code 72 - Failed to Select Rail A Purpose: Determine if an Electric Shifter was installed without recalibrating the transmission. B Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse, power and ground supplies to the TECU. 1. Key off. 2. Was a new Electric Shifter or TECU just installed without recalibrating the transmission? • Yes. Perform transmission calibration. Turn key on and allow the transmission to power up. Turn key off and wait 2 minutes. go to Step V. 1. Key off. 2. Inspect starter / battery and in-line fuse holder connections for integrity. 3. Measure voltage across batteries. Front of Transmission Transmission ECU VOLTS – + – + • No, go to Step B. V COM A Transmission Harness OEM Harness 36 38 Battery power (Non-switched power) run to starter or Battery 30 AMP fuse – – + + • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required and go to Step C. • If voltage is outside of range, repair or replace batteries and charge system as required. Repeat test. 226 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 72 - Failed to Select Rail Purpose: Verify proper ground path at 4-way diagnostic port. 1. Locate the diagnostic port on the Transmission Harness - located at the left rear corner of the transmission. D Purpose: Measure batter voltage at 4-way diagnostic port. 1. Key on. 2. Measure voltage between Pin B and Pin C. 2. Key on. 4-Pin Diagnostics Port 3. Measure voltage between Pin C and the battery negative post. VOLTS V B A C D COM A 4-Pin Diagnostics Port B A C D 4-way Battery Negative Post 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step E. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 © 2016 Eaton. All rights reserved 227 TRTS0930 Fault Code 72 - Failed to Select Rail | Fault Isolation Procedures E Purpose: Measure ignition voltage at 4-way diagnostic port. F Purpose: Visually inspect the Shift Bar housing, Electric Shifter and base transmission for signs of mechanical damage. 1. Key on. 1. Key off. 2. Measure voltage between Pin A and Pin C. 2. Remove electric shifter from Shift Bar housing. 3. Inspect the Shift Bar housing - Visually inspect shift rails and blocks. - Verify Shift Bar housing operation by confirming shift rails can physically engage each gear individually. - Confirm the Shift Bar housing can not engage two gears at the same time. 4-Pin Diagnostics Port B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step F. • If voltage is outside of range, Repair Ignition power supply to TECU. Fuse may be blown. Repeat test. 4. Inspect Electric Shifter - Check for mechanical issues with the Electric Shifter. - Visually inspect for badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leaks. - Check for a worn center shaft bushing (see TAIB-0814). 5. Inspect Base Transmission - Drain and inspect oil for debris. - Remove I-brake or PTO cover and inspect for main box mechanical failure. - Inspect sliding clutches and shift yokes for wear. • If no problem found, replace Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If problem found, repair as required. Go to Step V. 228 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 72 - Failed to Select Rail Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 72 appears go to Step A. to find error in testing. • If fault code other than 72 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 229 TRTS0930 Fault Code 73 - Failed to Engage Gear | Fault Isolation Procedures Fault Code 73 - Failed to Engage Gear J1587: MID 130 J1939: SA 3 SID 58 SPN 781 FMI 7 FMI 7 Overview Possible Causes This fault indicates the system cannot engage the desired gear. The system will continue attempting to engaged the desired gear after the fault is set. This fault code can be caused by any of the following: Vehicle must be moving and attempting to engage a gear and no electrical faults can be active. The system unsuccessfully attempts to engage a gear 5 times with no battery voltage faults. Conditions to Set Fault Code Active Conditions to Set Fault Code Active FMI 7 - The system is unable to engage a gear 5 times with no battery voltage faults. Fallback Fallback mode During Power-Up • • Mechanical issue with the shift bar housing • Damaged shift bar housing interlock parts Electric Shifter Detection • FMI 7: None. This fault can not be set at power-up. • New Electric Shifter installed and not recalibrated per the L-Letter (L-2003-30) • Mechanical issue with the Electric Shifter • Badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leak • Worn center shaft bushing (TAIB-0814) Base Transmission • Main box mechanical failure • Sliding clutch / shift yoke wear Transmission Electronic Control Unit (TECU) Fallback Mode During Operation • • When this fault is active, the transmission will continue to attempt to engage the gear. • The system will alternate the engine speed up and down in an attempt to achieve engagement. • The gear display may blink the destination gear. • The service light will not flash, nor will an F be displayed on the dash. • The diagnostic code will not be transmitted on the J1587 bus until fault codes have been requested by a service tool. New TECU installed and not recalibrated per the L-Letter (L-2005-04.) Engine • Inaccurately or not responding to the transmission speed control command. Conditions to Set Fault Code Inactive Conditions to Set Fault Code Active • 230 FMI 7 - The fault becomes Inactive when neutral is achieved. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 73 - Failed to Engage Gear Component Identification 2016.01.15 © 2016 Eaton. All rights reserved 231 TRTS0930 Fault Code 73 - Failed to Engage Gear | Fault Isolation Procedures Fault Code 73 - Failed to Engage Gear A Purpose: Determine if an Electric Shifter was installed without recalibrating the transmission. B Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse, power and ground supplies to the TECU. 1. Key off. 2. Was a new Electric Shifter or TECU just installed without recalibrating the transmission? • Yes, Perform transmission calibration. Turn key on and allow the transmission to power up. Turn key off and wait 2 minutes. go to Step V.. 1. Key off. 2. Inspect starter / battery and in-line fuse holder connections for integrity. 3. Measure voltage across batteries. Front of Transmission Transmission ECU • No, go to Step B. VOLTS V COM – + – + A Transmission Harness OEM Harness 36 38 Battery power (Non-switched power) run to starter or Battery 30 AMP fuse – – + + • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step C. • If voltage is outside of range, repair or replace batteries and charge system as required. Repeat test. 232 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Fault Isolation Procedures | Fault Code 73 - Failed to Engage Gear Purpose: Verify proper ground path at 4-way diagnostic port 1. Locate the diagnostic port on the Transmission Harness - located at the left rear corner of the transmission. D Purpose: Measure battery voltage at 4-way diagnostic port. 1. Key on. 2. Measure voltage between Pin B and Pin C. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. 4-Pin Diagnostics Port VOLTS V B A C D COM A 4-Pin Diagnostics Port B A C D 4-way Battery Negative Post B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step E. 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 © 2016 Eaton. All rights reserved 233 TRTS0930 Fault Code 73 - Failed to Engage Gear | Fault Isolation Procedures E Purpose: Measure ignition voltage at 4-way diagnostic port F Purpose: Visually inspect the Shift Bar housing, Electric Shifter and base transmission for signs of mechanical damage. 1. Key on. 1. Key off. 2. Measure voltage between Pin A and Pin C. 2. Remove electric shifter from Shift Bar housing. 3. Inspect the Shift Bar housing - Visually inspect shift rails and blocks. - Verify Shift Bar housing operation by confirming shift rails can physically engage each gear individually. - Confirm the Shift Bar housing can not engage 2 gears at the same time. 4-Pin Diagnostics Port B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step F. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown Repeat test. 4. Inspect Electric Shifter - Check for mechanical issues with the Electric Shifter. - Visually inspect for badly contaminated / gummed up / soiled Electric Shifter ball screw due to oil cooler leaks. - Check for a worn center shaft bushing (see TAIB-0814). 5. Inspect base transmission - Drain and inspect oil for debris. - Remove I-brake or PTO cover and inspect for main box mechanical failure. - Inspect sliding clutches and shift yokes for wear. • If no problem found, replace Electric Shifter and the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If problem found, repair as required. Go to Step V. 234 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Fault Isolation Procedures | Fault Code 73 - Failed to Engage Gear Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors and the negative battery cable. 3. Key on. 4. Clear fault codes, see “Fault Code Retrieval/Clearing” on page 5. 5. Drive the vehicle and attempt to reset the fault code. 6. Check for fault codes, see “Fault Code Retrieval/Clearing” on page 5. • If no fault codes, test complete. • If Fault Code 73 appears go to Step A. to find error in testing. • If fault code other than 73 appears, See “Fault Code Isolation Procedure Index” on page 8. 2016.01.15 © 2016 Eaton. All rights reserved 235 Fault Code 74 - Engine Speed Response Fault | Fault Isolation Procedures TRTS0930 Fault Code 74 - Engine Speed Response Fault J1587: MID 130 J1939: SA 3 PID 93/190 FMI 7 SPN 518/898 FMI 7 Overview This fault code indicates the transmission is unable to use system controls to synchronize during a shift. Detection If there is engine communication on the J1939 Link and the engine does not respond to transmission speed and torque commands, the code will set. Fallback If the failure occurs while moving, it could cause a 1-speed fallback. Once the vehicle is stopped, starting gear and reverse gear can be engaged. Possible Causes This fault code can be caused by any of the following: • 236 Engine control system © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 74 - Engine Speed Response Fault Component Identification Engine ECM Engine Torque Value 2016.01.15 © 2016 Eaton. All rights reserved 237 Fault Code 74 - Engine Speed Response Fault | Fault Isolation Procedures TRTS0930 Fault Code 74 - Engine Speed Response Fault A Purpose: Check for active or Inactive fault codes. Contact vehicle OEM for further direction. 1. Key on. 2. Retrieve fault codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 74 is Active, contact the OEM because the engine is failing to respond to the transmissions command during a shift. • If fault code is not Active, test complete. 238 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 74 - Engine Speed Response Fault © 2016 Eaton. All rights reserved 239 Fault Code 75 - Power Down In Gear | Fault Isolation Procedures TRTS0930 Fault Code 75 - Power Down In Gear J1587: MID 130 J1939: SA 3 SID 60 SPN 560 FMI 14 FMI 14 Overview This fault is detected when the vehicle is powered-down in any gear position other than neutral. Note: This code will only be set Inactive Detection The Transmission Electronic Control Unit (TECU) monitors shift device position and electric shifter position during vehicle shut down. If a non-neutral shift device position and in gear position are detected during vehicle shut down, this code will be set. Fallback No Fallback mode. This is a non driving, power-down fault. It may cause a dash to appear in the gear display during power-up if the transmission is torque locked after shutting down in gear. Possible Causes This fault code can be caused by any of the following: • 240 Improper shut down procedure © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 75 - Power Down In Gear Component Identification VOLUME CONTROL R N SERVICE D H SHIFT L Eaton Fuller Transmissions Pushbutton Shift Control 2016.01.15 Eaton Shift Lever © 2016 Eaton. All rights reserved 241 Fault Code 75 - Power Down In Gear | Fault Isolation Procedures TRTS0930 Fault Code 75 - Power Down In Gear A Purpose: Check for active or Inactive fault codes. 1. Key on. 2. Retrieve Codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 75 is Inactive, no action necessary. This code indicates the driver powered down the system prior to selecting neutral. • Explain to driver, shift selector must be in neutral before powering down to prevent a stuck-in-gear situation and/or a power-up no crank situation. 242 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 75 - Power Down In Gear © 2016 Eaton. All rights reserved 243 Fault Code 81 - Gear Engagement Detected | Fault Isolation Procedures TRTS0930 Fault Code 81 - Gear Engagement Detected J1587: MID 130 J1939: SA 3 SID 47 SPN 780 FMI 7 FMI 7 Overview The transmission controller has detected that the shift finger position indicates neutral and a comparison of input and main shaft speeds indicate the transmission is in gear. The comparison of shaft speeds is only performed when the vehicle is moving and a shift is in process. Detection • The fault is detected after the Transmission Electronic Control Unit (TECU) powers up and a non-neutral condition is detected during a shift. • FMI 7 - The transmission controller detected an inaccurate finger position. Conditions to Set Fault Code Active Conditions to Recreate Fault • Only set during a shift. Fallback This fault causes an in-place fallback. The transmission will remain in current gear. Conditions to Set Fault Code Inactive Conditions to Clear Fault • The fault becomes Inactive after power down. Possible Causes This fault code can be caused by any of the following: • 244 Worn internal transmission components. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 81 - Gear Engagement Detected Component Identification Transmission 2016.01.15 © 2016 Eaton. All rights reserved 245 Fault Code 81 - Gear Engagement Detected | Fault Isolation Procedures TRTS0930 Fault Code 81 - Gear Engagement Detected A Purpose: Check for active or Inactive fault codes. Contact Eaton support for further direction. 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 81 is active or Inactive, Customer - Call Eaton at 1-800-826-HELP (4357). CSC - Call Technician Service. 246 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 81 - Gear Engagement Detected © 2016 Eaton. All rights reserved 247 Fault Code 83 - Shift Lever Missing | Fault Isolation Procedures TRTS0930 Fault Code 83 - Shift Lever Missing J1587: MID 130 J1939: SA 3 SID 18, 19 FMI 14 SPN 751, 752 FMI 7, 12 Overview This fault code indicates the Eaton Cobra Lever or the OEM Shift Lever is not sensing any lever positions. Detection Starting at key on and throughout operation, the Transmission Electronic Control Unit (TECU) constantly measures the feedback from the Shift Lever circuit. If the Shift Lever reports no lever positions are sensed, the fault code is set. Fallback This fault causes a downshift only and shifts to neutral when the vehicle stops. Possible Causes This fault code can be caused by any of the following: • 248 Eaton Cobra Lever or OEM Shift Lever © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 83 - Shift Lever Missing Component Identification Eaton Shift Lever 2016.01.15 © 2016 Eaton. All rights reserved 249 Fault Code 83 - Shift Lever Missing | Fault Isolation Procedures TRTS0930 Fault Code 83 - Shift Lever Missing A Purpose: Check for active or Inactive fault codes. 1. Key on. 2. Retrieve codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 83 is Active, replace Eaton Cobra Lever or OEM Shift Lever. • If Fault Code 83 is Inactive, test complete. 250 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 83 - Shift Lever Missing © 2016 Eaton. All rights reserved 251 Fault Code 84 - Shift Control Device Not Configured | Fault Isolation Procedures TRTS0930 Fault Code 84 - Shift Control Device Not Configured J1587: MID 130 J1939: SA 3 SID 18, 19 FMI 13 SPN 751, 752 FMI 13 Overview This fault indicates a new Transmission Electronic Control Unit (TECU) has not detected a Shift Control device. Detection The fault is detected the first time the system is powered up. The TECU looks for a shift control device if none are detected the system will set this code. Note: The fault will only be set active. Fallback No crank at power-up. Possible Causes This fault code can be caused by any of the following: 252 • Damaged OEM Wiring Harness between TECU and Shift Control device after new TECU is installed. • Disconnected Shift Control device after new TECU is installed. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 84 - Shift Control Device Not Configured Component Identification Vehicle Harness 38-way Connector 2016.01.15 © 2016 Eaton. All rights reserved 253 Fault Code 84 - Shift Control Device Not Configured | Fault Isolation Procedures TRTS0930 Fault Code 84 - Shift Control Device Not Configured A Purpose: Confirm Shift Control device is properly installed. Check for active or Inactive fault codes. 1. Verify Shift Control device is connected to the OEM wiring. 2. Key on. 3. Retrieve fault codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 84 is Active, repair OEM wiring between TECU and Shift Control device. 254 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 84 - Shift Control Device Not Configured © 2016 Eaton. All rights reserved 255 Fault Code 85 - Shift Control Device Incompatible | Fault Isolation Procedures TRTS0930 Fault Code 85 - Shift Control Device Incompatible J1587: MID 130 J1939: SA 3 SID 18 SPN 751 FMI 12 FMI 12 Overview This fault indicates the Transmission Electronic Control Unit (TECU) has detected a non compatible Shift Control device. Detection The TECU looks for a Shift Control device at system power-up. If a non compatible shift control device is detected the system will set this code. Fallback This fault causes an in-place fallback Possible Causes This fault code can be caused by any of the following: • 256 Non compatible Shift Control device © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 85 - Shift Control Device Incompatible Component Identification VOLUME CONTROL R N SERVICE D H SHIFT L Eaton Fuller Transmissions Pushbutton Shift Control 2016.01.15 Eaton Shift Lever © 2016 Eaton. All rights reserved 257 Fault Code 85 - Shift Control Device Incompatible | Fault Isolation Procedures TRTS0930 Fault Code 85 - Shift Control Device Incompatible A Purpose: Confirm Shift Control device part number. Ensure proper device installed. 1. Verify Shift Control device is connected to the OEM wiring. 2. Key on. 3. Retrieve fault codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 85 is Active, verify correct Shift Control device is installed on vehicle. 258 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 85 - Shift Control Device Incompatible © 2016 Eaton. All rights reserved 259 Fault Code 99 - Direction Mismatch | Fault Isolation Procedures TRTS0930 Fault Code 99 - Direction Mismatch J1587: MID 130 J1939: SA 3 SID 58 SPN 781 FMI 14 FMI 14 Overview The transmission controller is monitoring the Gear Position sensor and has determined the Electric Shifter is moving in the opposite intended direction. Detection • The fault can be detected any time after the Transmission Electronic Control Unit (TECU) powers up and a non-neutral mode is selected. • FMI 14 - The transmission controller detected an incorrect Electric Shifter position. Conditions to Set Fault Code Active Conditions to Recreate Fault • None Fallback This fault causes an in-place fallback. The transmission will remain in current gear. Conditions to Set Fault Code Inactive Conditions to Clear Fault • The fault becomes Inactive after power down. Possible Causes This fault code can be caused by the following: 260 • Internal transmission controller fault. • Transmission wire harness shorted. • Electric Shifter failure. © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Fault Isolation Procedures | Fault Code 99 - Direction Mismatch Component Identification Transmission Controller 2016.01.15 XY Shifter Transmission Harness © 2016 Eaton. All rights reserved 261 Fault Code 99 - Direction Mismatch | Fault Isolation Procedures TRTS0930 Fault Code 99 - Direction Mismatch A Purpose: Check for active or Inactive fault codes. Contact Eaton technical support for further direction. 1. Key on. 2. Retrieve fault codes. See “Fault Code Retrieval/Clearing” on page 5. • If Fault Code 99 is Active or Inactive, Customer - Call Eaton at 1-800-826-HELP (4357). CSC - Call Technician Service. 262 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Fault Isolation Procedures | Fault Code 99 - Direction Mismatch © 2016 Eaton. All rights reserved 263 TRTS0930 Up/Down Button Test | Symptom Isolation Procedures Up/Down Button Test Overview This symptom-driven test is performed if unable to shift the transmission with the Up/Down buttons, and there are no Active or Inactive codes. Detection The shift control has no fault detection capability for this failure. The failure is observed by the driver when operating the vehicle. Fallback There is no fallback for this symptom. Possible Causes This symptom can be caused by any of the following: 264 • Push button shift control • Shift Lever © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | Up/Down Button Test Component Identification Side view of pushbutton shift control VOLUME CONTROL R N SERVICE D H SHIFT L Eaton Fuller Transmissions Pushbutton Shift Control 2016.01.15 © 2016 Eaton. All rights reserved Eaton Shift Lever 265 TRTS0930 Up/Down Button Test | Symptom Isolation Procedures Up/Down Button Test A Purpose: Drive vehicle and attempt to complete manual button shifts in Manual Mode. 1. Start engine. 2. Place Shift Device in manual. 3. Drive the vehicle using the buttons to initiate upshifts and downshifts, when conditions permit. • If the up and down buttons are working properly, the transmission will make upshifts and downshifts, test complete. • If the transmission does not make upshifts or downshifts, replace Shift Control. Repeat test. 266 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Symptom Isolation Procedures | Up/Down Button Test © 2016 Eaton. All rights reserved 267 Start Enable Relay Contact Test | Symptom Isolation Procedures TRTS0930 Start Enable Relay Contact Test Overview This symptom-driven test is performed if the engine does not crank with the Shift Lever in neutral, and there are no Active or Inactive codes. Detection The Transmission Electronic Control Unit (TECU) has no fault detection capability for this failure. The failure is observed by the driver when operating the vehicle. To observe this failure, attempt to start the vehicle. Fallback This symptom has no affect on vehicle operation; however, if the failure occurred before the engine was started, it is possible the engine will not start. Possible Causes This symptom can be caused by any of the following: 268 • Start Enable Relay • Starter Solenoid wiring • Vehicle Harness © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | Start Enable Relay Contact Test Component Identification 3 2 1 4 1. 38-Way Transmission Harness Connector 2. Transmission Electronic Control Unit (TECU) 3. 5-Way Start Enable Relay Socket 4. 4-Way Diagnostic Connector 2016.01.15 © 2016 Eaton. All rights reserved 269 TRTS0930 Start Enable Relay Contact Test | Symptom Isolation Procedures 2 1 26 4 3 87 87 86 85 30 Starter 26 32 4 IGN 1. Transmission Electronic Control Unit (TECU) 2. 38-Way Vehicle Harness Connector 3. 5-Way Start Enable Relay Socket 4. 5-Way Start Enable Relay 5 6 + OFF + ACC ON 85 4 86 32 87 30 26 87A ACC OFF ON START 85 Starter 4 86 32 87 30 87A 26 START Starter Start Enable Relay Circuit States (Normally Open) 5. Open Relay - Key Off (Non-energized State) 6. Closed Relay - Key On and Transmission Confirmed in Neutral (Energized State) 270 Battery Voltage Switched Battery from TECU Ground Communication Ignition Voltage Switched 5V from TECU Switched Ground Relay/Solenoid Driver © 2016 Eaton. All rights reserved Signal 2016.01.15 TRTS0930 Symptom Isolation Procedures | Start Enable Relay Contact Test 1 2 A B C 25 17 31 1. Transmission Electronic Control Unit (TECU) 2. 4-Way Diagnostic Connector 2016.01.15 Battery Voltage Switched Battery from TECU Ground Communication Ignition Voltage Switched 5V from TECU Switched Ground Relay/Solenoid Driver © 2016 Eaton. All rights reserved Signal 271 TRTS0930 Start Enable Relay Contact Test | Symptom Isolation Procedures Start Enable Relay Contact Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Key off. 1. Locate diagnostic port on Transmission Harness. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. VOLTS V COM – + – + A − C C • If voltage is 11–13 volts on a 12-volt system or 22 to 26 on a 24 volt system, proceed with battery load test. Repair or replace batteries as required and go to Step B. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. 272 © 2016 Eaton. All rights reserved • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 TRTS0930 C Symptom Isolation Procedures | Start Enable Relay Contact Test Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. A A B C B C C • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 2016.01.15 C © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. 273 TRTS0930 Start Enable Relay Contact Test | Symptom Isolation Procedures E Purpose: Visually inspect Start Enable Relay wiring and confirm that it is wired per requirements. Confirm if the engine will crank. G Purpose: “Jump” the Start Enable Relay and confirm if the engine will crank. 1. Key on. 1. Key off. 2. Disconnect negative battery cable. 2. Disconnect negative battery cable. 3. Reconnect Vehicle Harness 38-way connector. 3. Disconnect Vehicle Harness 38-way connector. 4. Reconnect negative battery cable. 4. Reconnect negative battery cable. 5. Place a jumper wire across connector contact 30 and contact 87. 5. Key on. 6. Engage starter. Note: The Start Enable Relay must be wired according to Eaton GEN III requirements (shown on previous page) for this test to work properly. If wired differently, consult OEM for correct wiring schematic. ! Warning: Make sure the parking brake is set before jumping the Start Enable Relay. 6. Key on. Verify neutral on Gear Display. 7. Engage starter. • If engine cranks, go to Step F. 86 87 85 • If engine does not crank, go to Step G. 30 F Purpose: Remove the Start Enable Relay and confirm if the engine will crank. • If engine cranks, replace the Start Enable Relay. go to Step H. • If engine does not crank, refer to OEM for repair of Vehicle Harness or starter. 1. Key off. 2. Remove the Start Enable Relay. 3. Key on. 4. Engage starter. • If vehicle cranks, repair short to power on Vehicle Harness. go to Step V. • If vehicle does not crank, replace Start Enable Relay. go to Step V. 274 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | Start Enable Relay Contact Test Purpose: Verify continuity of the Start Enable Latch wire. H V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Disconnect negative battery cable. 2. Reconnect all connectors. 3. Disconnect Vehicle Harness 38-way connector. 3. Key on. 4. Disconnect the Start Enable Relay. 4. Start the engine to determine whether the Start Enable Relay contact complaint has been repaired. 5. Measure resistance between Pin 87 of the Start Enable Relay connector and Pin 26 of the Vehicle Harness 38-Way connector. • If engine starts, test complete. • If engine does not start go to Step A. to error in testing. 26 87 26 87 • If resistance is 0 to 0.3 ohms, go to Step V. • If resistance is greater than 10K ohm, repair wiring and go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 275 TRTS0930 J1587 Data Link Test | Symptom Isolation Procedures J1587 Data Link Test Overview This symptom-driven test is performed if the ServiceRanger, a PC-based Service Tool, does not work. Detection The service technician observes the failure when operating ServiceRanger. To observe this failure, simply connect ServiceRanger to the transmission via the J1587 Diagnostic Connector located in the cab. Fallback There is no fallback mode for the J1587 Data Link. Possible Causes This symptom can be caused by any of the following: 276 • J1587 Data Link Harness • ServiceRanger • Transmission Electronic Control Unit (TECU) © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | J1587 Data Link Test Component Identification Transmission ECU +12 volts battery J1587 data link 10 OEM 11 9-way 6-way diagnostic connector diagnostic connector A ATA+ B ATA– C + Battery D E Ground F 2016.01.15 D E F B A E D C F A B C J G H © 2016 Eaton. All rights reserved GROUND A Ground B + Battery C D E F ATA+ G ATAH J 277 TRTS0930 J1587 Data Link Test | Symptom Isolation Procedures J1587 Data Link Test A Purpose: Measure battery voltage supply to the vehicle diagnostic connector. B Purpose: Verify continuity of the J1587 Plus wire from the TECU to the vehicle diagnostic connector. 1. Key off. 1. Key off. 2. Measure voltage either between 6-Way Diagnostic Connector Pin C and Pin E or 9-Way Diagnostic Connector Pin B and Pin A. 2. Disconnect negative battery cable. • If voltage is within 0.6 volts of battery voltage, go to Step B. 3. Disconnect Vehicle Harness 38-Way Connector. 4. Measure resistance from Vehicle Harness 38-Way Connector Pin 10 and either 6-Way Diagnostic Connector Pin A or 9-Way Diagnostic Connector Pin F. • If voltage is outside of range, repair battery or ground wire to vehicle Diagnostic connector. Go to Step V. Pins • If resistance is 0–0.3 ohms, go to Step C. • If resistance is outside of range, repair Vehicle Harness. Repeat this step. Measurement Pins Measurement C to E 10 to A B to A 10 to F 278 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | J1587 Data Link Test Purpose: Test the J1587 Plus wire for a short to ground through the vehicle diagnostic connector. 1. Measure resistance between either 6-Way Diagnostic Connector Pin A or 9-Way Diagnostic Connector Pin F and ground. • If resistance is OL, go to Step D. E 1. Measure resistance between either 6-Way Diagnostic Connector Pin B or 9-Way Diagnostic Connector Pin G and ground. • If resistance is less than 10K ohm, repair Vehicle Harness. Go to Step V. Pins Purpose: Test the J1587 negative (–) wire for a short to ground through the vehicle diagnostic connector. • If resistance is OL, go to Step V. • If resistance is less than 10K ohm, repair Vehicle Harness. Go to Step V. Measurement Pins Measurement A to Ground B to Ground F to Ground G to Ground D Purpose: Verify continuity of the J1587 negative (–) wire from the TECU to the vehicle diagnostic connector. 1. Measure resistance between Vehicle Harness 38-Way Connector Pin 11 and either 6-Way Diagnostic Connector Pin B or 9-Way Diagnostic Connector Pin G. • If resistance is 0–0.3 ohms, go to Step E. • If resistance is outside of range, repair Vehicle Harness and go to Step V. Pins Measurement 11 to B 11 to G 2016.01.15 © 2016 Eaton. All rights reserved 279 TRTS0930 J1587 Data Link Test | Symptom Isolation Procedures V Purpose: Verify repair. 1. Key on. 2. Connect to ServiceRanger. • If ServiceRanger functions correctly, test complete. • If ServiceRanger does not function correctly go to Step A. find error in testing. 280 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Symptom Isolation Procedures | J1587 Data Link Test © 2016 Eaton. All rights reserved 281 Front Box Control Test | Symptom Isolation Procedures TRTS0930 Front Box Control Test Overview This symptom-driven test is performed if a dash is displayed on the gear display, and there are no active or Inactive codes. Detection Turn the key on and watch the Gear Display. If the Gear Display shows “-” constantly, the Transmission Electronic Control Unit (TECU) was not able to confirm front box control. Any time the service light is flashing, go to Diagnostics Procedure. Fallback This fault causes an in-place fallback while moving, and it causes a failure during system initialization. A dash will appear on the Gear Display. Possible Causes This symptom can be caused by any of the following: 282 • Low power to gear select motor • Electric shifter • Gear Select Sensor • Yoke / clutch / main shaft • Shift Bar housing • Dragging clutch • Torque locked in gear © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | Front Box Control Test Component Identification Shift bar housing Electric shifter Transmission controller 2016.01.15 Base Transmission © 2016 Eaton. All rights reserved 283 TRTS0930 Front Box Control Test | Symptom Isolation Procedures Front Box Control Test A Purpose: Visually observe the gear display after power-up. B Purpose: Visually observe the gear display when placing the transmission into Drive. 1. Key on. 1. Key on. 2. Depress clutch pedal (if equipped) half way to the floor. 2. Place Shift Device in neutral. 3. Place Shift Device in neutral. 4. Observe Gear Display. 3. Depress clutch pedal (if equipped) half way to the floor. If it is a two pedal design apply the service brake. 4. Select Drive • If Gear Display shows N, go to Step B. 5. Observe Gear Display. • If service light is flashing, see “Diagnostic Procedures” on page 3. • If Gear Display shows: “-” or a flashing gear with no arrows, go to Step C. • If Gear Display shows a solid gear, test complete. • If service light is flashing, See “Diagnostic Procedures” on page 3. • If Gear Display shows a flashing gear with no arrows, go to Step C. 284 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | Front Box Control Test Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. E Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage between Pin B and Pin C. • If voltage is within 0.6 volts of battery voltage, go to Step F. 3. Measure voltage across batteries. • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required and go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. F D Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Key on. 2. Measure voltage between Pin A and Pin C. 1. Locate diagnostic port on Transmission Harness. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. • If voltage is within 0.6 volts of battery voltage, go to Step G. • If voltage is outside of range, repair Ignition power supply to TECU. Fuse may be blown. Repeat test. • If voltage is 0.70 volts or less, go to Step E. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 © 2016 Eaton. All rights reserved 285 TRTS0930 Front Box Control Test | Symptom Isolation Procedures G Purpose: Remove Electric Shifter from the Shift Bar Housing and inspect the mechanical transmission. V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Reconnect all connectors. 2. Remove Electric Shifter from Shift Bar housing. 3. Inspect the Shift Bar housing: - Shift Blocks - Shift Rails - Inspect Electric Shifter for evidence of lube contamination. 3. Place Shift Control into neutral. 4. Key on. Note: See if the Shift Bar housing can engage two gears at the same time to verify interlock operation. • If Gear Display displays a solid N, test complete. • If Gear Display does not display a solid N, find error in testing, return to go to Step A. • If no problem found, replace Electric Shifter go to Step V. • If problem found, repair as required go to Step V. 286 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Symptom Isolation Procedures | Front Box Control Test © 2016 Eaton. All rights reserved 287 AutoShift Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures TRTS0930 AutoShift Will Not Engage a Gear from Neutral Test Overview This symptom-driven test is performed if the transmission does not engage a gear, and there are no active or Inactive codes. Detection If the Transmission Electronic Control Unit (TECU) is unable to provide a fault code, the driver may observe this failure as the transmission not initiating or completing a shift. The driver may observe this failure as the transmission neutralizes. Fallback There is no fallback mode for this symptom. Possible Causes This symptom can be caused by any of the following: 288 • Input Shaft Speed Sensor • Transmission • Clutch Brake/Clutch • Transmission Harness • TECU © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | AutoShift Will Not Engage a Gear from Neutral Test Component Identification Transmission Harness 38-way Connector Shift Bar Housing Main Shaft D1 D2 A B Input shaft speed sensor Transmission Harness 38-way Connector 2016.01.15 © 2016 Eaton. All rights reserved 289 TRTS0930 AutoShift Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures AutoShift Will Not Engage a Gear from Neutral Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Key off. 1. Locate diagnostic port on Transmission Harness. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS VOLTS – + B A C D V COM A Battery Negative Post V COM A – + 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. 290 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | AutoShift Will Not Engage a Gear from Neutral Test Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 2016.01.15 B - Service Bat. + C - Service Bat. A - Service Ignition + © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, Repair ignition power supply to TECU. Fuse may be blown. Repeat test. 291 TRTS0930 AutoShift Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures E Purpose: Visually observe the gear display when placing the transmission into Drive. F Purpose: Monitor Input Shaft Speed in ServiceRanger. 1. Key on. 1. Key off. 2. Depress clutch pedal. 2. Connect ServiceRanger, a PC-based Service Tool. 3. Start engine. 3. Start engine. Release clutch pedal. 4. Release clutch pedal to verify input shaft speed. 4. View Input Shaft speed. 5. Depress clutch pedal. • If Input Shaft speed exists, contact your local Eaton Representative or call 1-800-826-HELP (4357). 6. Place Shift Lever in D. 7. Observe Gear Display. • If input shaft speed does not exist, go to Step G. • If Gear Display shows a solid N and the warning tone sounds, go to Step F. • If Gear Display shows a flashing gear with arrows, go to Step M. • If Gear Display shows a flashing gear with no arrows, See “Front Box Control Test” on page 282. • If Gear Display shows a solid gear but the vehicle will not move, contact your local Eaton Representative or call 1-800-826-HELP (4357). G Purpose: Measure the resistance of the Input Shaft Speed Sensor through the Transmission Harness. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure the resistance between the Transmission Harness 38-way connector Pin 7 and Pin 8. OHMS Front View Transmission ECU Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 22 21 36 Transmission Harness 38-way Connector • If resistance is 2K to 4.5K ohm, go to Step H. • If resistance is outside of range, go to Step J. 292 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 H Symptom Isolation Procedures | AutoShift Will Not Engage a Gear from Neutral Test Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground through the Transmission Harness. 1. Measure resistance between the Transmission Harness 38-way connector Pin 7 and ground. Front View Transmission ECU Connector J Purpose: Measure the resistance of the Input Shaft Speed Sensor at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. OHMS OHMS A 14 35 31 32 33 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 29 37 13 30 34 38 21 V COM B A 22 V 36 COM A Transmission Harness 38-way Connector • If resistance is OL,go to Step I. • If resistance is less than 10K ohm, go to Step J. • If resistance is 2K to 4.5K ohm, go to Step K. • If resistance is outside of range, go to Step I. I Purpose: Visually remove and inspect the Input Shaft Speed Sensor for contamination or damage. 1. Inspect Input Shaft Speed Sensor for contamination or damage. • If no problem found, go to Step L. • If problem found or you were sent here from Step J or K, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor Inspect the upper countershaft PTO gear for damage. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 293 AutoShift Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures K Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground at the Input Shaft Speed Sensor. L TRTS0930 Purpose: Verify mechanical movement of the upper countershaft within the transmission. 1. Key off. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. 3. Turn the Input Shaft and verify the Upper Countershaft is rotating. OHMS A 2. Verify the Upper Countershaft is turning. B V COM • If Upper Countershaft is turning, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) A GROUND Go to Step V. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness • If Upper Countershaft is not turning, contact your Eaton Representative or call Eaton at 1-800-826-HELP (4357). Go to Step V. • If resistance is less than 10K ohm, go to Step I. 294 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 M Symptom Isolation Procedures | AutoShift Will Not Engage a Gear from Neutral Test Purpose: Monitor Input Shaft Speed in ServiceRanger. V Purpose: Verify repair. 1. Connect PC-based service tool. 1. Key off. 2. Start engine. 2. Reconnect all connectors. 3. Depress clutch pedal. 3. Key on. 4. View input shaft speed. 4. Drive the vehicle to determine whether the complaint has been repaired. • If input shaft speed does not drop below 150 RPM, clutch is out of adjustment and/or Input Shaft Brake (Clutch Brake) is malfunctioning. Adjust clutch per manufacturer’s specifications. go to Step V. • If the transmission engages a gear, test complete. • If the transmission does not engage a gear go to Step A. to find error in testing. • If input shaft speed drops below 150, test complete and go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 295 UltraShift DM3 Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures TRTS0930 UltraShift DM3 Will Not Engage a Gear from Neutral Test Overview This symptom-driven test is performed if the transmission does not engage a gear, and there are no active or Inactive codes. Detection If the Transmission Electronic Control Unit (TECU) is unable to provide a fault code, the driver may observe this failure as the transmission not initiating or completing a shift. The driver may observe this failure as the transmission neutralizes. Fallback There is no fallback mode for this symptom. Possible Causes This symptom can be caused by any of the following: 296 • Input Shaft Speed Sensor • Transmission • Inertia Brake • Clutch/Clutch Brake • OEM Service Brake Switch Operation • TECU • Transmission Harness © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | UltraShift DM3 Will Not Engage a Gear from Neutral Test Component Identification Transmission Harness 38-way Connector Shift Bar Housing Main Shaft D1 D2 A B Transmission Harness 38-way Connector H1 H2 ! A B Input shaft speed sensor Inertia brake Warning: Do not load test at diagnostic port. 2016.01.15 © 2016 Eaton. All rights reserved 297 UltraShift DM3 Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures TRTS0930 UltraShift DM3 Will Not Engage a Gear from Neutral Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. C Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key off. 2. Key on. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage between Pin B and Pin C. • If voltage is within 0.6 volts of battery voltage, go to Step D. 3. Measure voltage across batteries. • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. D B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Key on. 2. Measure voltage between Pin A and Pin C. 1. Locate diagnostic port on Transmission Harness. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 298 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 E Symptom Isolation Procedures | UltraShift DM3 Will Not Engage a Gear from Neutral Test Purpose: Visually observe the gear display when placing the transmission into Drive. F Purpose: Monitor Input Shaft Speed in ServiceRanger. 1. Key on. 1. Key off. 2. Start engine. 2. Connect PC-based Service Tool. 3. Apply service brake while selecting D. 3. Start engine. Increase RPM and hold above 1000 RPM. 4. Observe Gear Display. Note: Using a ServiceRanger a PC-based Service Tool, verify OEM service brake operation. 4. View Input Shaft speed. • If Input Shaft speed exists, contact your Eaton Representative or call Eaton at 1-800-826-HELP (4357). • If Gear Display shows a solid N and the warning tone sounds, go to Step F. • If Input Shaft speed does not exist, go to Step G. • If Gear Display shows a flashing gear with arrows, go to Step M. • If Gear Display shows a flashing gear with no arrows, See “Front Box Control Test” on page 282. • If Gear Display shows a solid gear but the vehicle will not move, contact your Eaton Representative or call Eaton at 1-800-826-HELP (4357). G Purpose: Measure the resistance of the Input Shaft Speed Sensor through the Transmission Harness. 1. Key off. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure the resistance between the Transmission Harness 38-way connector Pin 7 and Pin 8. • If resistance is 2K to 4.5K ohm, go to Step H. • If resistance is outside of range, go to Step J. 2016.01.15 © 2016 Eaton. All rights reserved 299 UltraShift DM3 Will Not Engage a Gear from Neutral Test | Symptom Isolation Procedures H Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground through the Transmission Harness. 1. Measure resistance between the Transmission Harness 38-way connector Pin 7 and ground. • If resistance is OL, go to Step I. J TRTS0930 Purpose: Measure the resistance of the Input Shaft Speed Sensor at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. • If resistance is less than 10K ohm, go to Step J. • If resistance is 2K to 4.5K ohm, go to Step K. • If resistance is outside of range, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor Go to Step V. I Purpose: Visually remove and inspect the Input Shaft Speed Sensor for contamination or damage. 1. Inspect Input Shaft Speed Sensor for contamination or damage. • If no problem found, go to Step L. • If problem found, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor K Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground at the Input Shaft Speed Sensor. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. and inspect the upper countershaft PTO gear for damage. Go to Step V. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor Go to Step V. 300 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 L Symptom Isolation Procedures | UltraShift DM3 Will Not Engage a Gear from Neutral Test Purpose: Verify mechanical movement of the upper countershaft within the transmission. N Purpose: Perform Inertia Brake Test using ServiceRanger. 1. Key off. 1. Key on. 2. Turn the Input Shaft and verify the upper countershaft is rotating. 2. Make sure the PTO is off. • If upper countershaft is turning, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) 3. Connect ServiceRanger a PC-based Service Tool and select Advanced Product Functions. 4. Start engine. 5. Select Inertia Brake Test. 6. Run test and follow instructions. Go to Step V. • Test passes, replace clutch and go to Step V. • If upper countershaft is not turning, contact your Eaton Representative or call Eaton at 1-800-826- HELP (4357) for a repair strategy. • Test fails, replace the: - Medium-Duty Inertia Brake - Heavy-Duty Inertia Brake Go to Step V. • Test aborts, correct displayed test failure condition and retest. M Purpose: Monitor Input Shaft Speed in ServiceRanger. 1. Connect PC-based service tool. V 2. Start engine Purpose: Verify repair. 3. View input shaft speed. • If input shaft speed stays above 150 RPM, clutch is dragging, go to Step N. • If input shaft speed drops below 150 RPM, test complete and go to Step V. 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Drive the vehicle to determine whether the complaint has been repaired. • If the transmission engages a gear, test complete. • If the transmission does not engage a gear go to Step A. to find error in testing. 2016.01.15 © 2016 Eaton. All rights reserved 301 UltraShift AW3 Clutch Engagement Test | Symptom Isolation Procedures TRTS0930 UltraShift AW3 Clutch Engagement Test Overview This symptom-driven test is performed if a clutch engagement complaint exists, and there are no active or Inactive codes. Detection There is no detection other than a driver complaint. Fallback There is no fallback mode for clutch engagement complaint; however, it may effect vehicle performance. Possible Causes This symptom can be caused by any of the following: 302 • Low fluid level • Inertia Brake • Clutch calibration • Transmission © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | UltraShift AW3 Clutch Engagement Test Component Identification Inertia Brake WetClutch Fluid 2016.01.15 © 2016 Eaton. All rights reserved 303 TRTS0930 UltraShift AW3 Clutch Engagement Test | Symptom Isolation Procedures UltraShift AW3 Clutch Engagement Test A Purpose: Inspect the transmission fluid level. C Purpose: Bring engine up to operating temperature and test the clutch engagement operation. 1. Place transmission in neutral. 1. Key on. 2. Allow engine to idle at 600 to 700 RPM for a minimum of 2 minutes. Ensure transmission fluid temperature is 60 to 120 degrees F (16 to 49 degrees C) 2. Engine running, allow engine to reach operating temperature. 4. Start vehicle. 3. Check transmission fluid level. • If fluid level is at COLD-FULL mark, go to Step B. • If fluid level is below the COLD-ADD mark, correct fluid level, check for leaks. Drive Vehicle, if clutch engagement complaint exists, repeat this step. B 3. Key off. 5. Allow vehicle to idle in neutral for a minimum of 2 minutes. 6. Drive vehicle. • If clutch engagement complaint does not change, go to Step D. • If clutch engagement complaint is corrected, test complete. Purpose: Visually inspect the torsional coupler. 1. Remove the flywheel inspection cover and inspect the rubber coupler for damage or shear. • If no damage is observed, go to Step C. • If damage is observed, replace the Torsional Coupler. go to Step V. 304 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 D Symptom Isolation Procedures | UltraShift AW3 Clutch Engagement Test Purpose: Disconnect the Inertia Brake from the Transmission Harness and test the clutch engagement operation. V Purpose: Verify repair. 1. Key Off. 1. Key off. 2. Reconnect Transmission Harness to Inertia Brake. 2. Disconnect Transmission Harness from the Inertia Brake. 3. Key on. 3. Key on. 4. Drive the vehicle to determine whether the complaint has been repaired. 4. Drive vehicle (Flashing Service Light will exist). • If clutch engagement complaint does not change, Contact your Eaton Representative or call Eaton at 1-800-826-HELP (4357). • If clutch engagement complaint is corrected, replace the: - Medium-Duty Inertia Brake - Heavy-Duty Inertia Brake • If shift complaint has not been repaired, contact your Eaton Representative or call Eaton at 1-800-826-HELP (4357). • If the shift complaint has been repaired, test complete. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 305 AutoShift AS3 Shift Complaint Test | Symptom Isolation Procedures TRTS0930 AutoShift AS3 Shift Complaint Test Overview This symptom-driven test is performed if a shift complaint exists, and there are no active or Inactive codes. Detection There is no detection other than a driver complaint. Fallback There is no fallback mode for a shift complaint; however, it may affect vehicle performance. Possible Causes This fault code can be caused by any of the following: 306 • Electric Shifter • Range system • Splitter system • Input Shaft Speed Sensor • Transmission Harness • Shift Bar housing • Transmission Electronic Control Unit (TECU) © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | AutoShift AS3 Shift Complaint Test Component Identification Input Shaft Speed Sensor Range System Splitter System Transmission Harness Transmission ECU 2016.01.15 © 2016 Eaton. All rights reserved 307 TRTS0930 AutoShift AS3 Shift Complaint Test | Symptom Isolation Procedures AutoShift AS3 Shift Complaint Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Key off. 1. Locate diagnostic port on Transmission Harness. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 2. Key on. 3. Measure voltage across batteries. 3. Measure voltage between Pin C and the battery negative post. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS VOLTS – + B A C D V COM A Battery Negative Post V COM A – + 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required. Go to Step B. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat this step. 308 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | AutoShift AS3 Shift Complaint Test Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. E Purpose: Monitor Input Shaft Speed in ServiceRanger. 1. Connect PC-based service tool and monitor Input Shaft speed with Clutch Pedal released. • If input shaft speed matches engine RPM, go to Step K. • If Input shaft speed reads 0, go to Step F. 2016.01.15 © 2016 Eaton. All rights reserved 309 TRTS0930 AutoShift AS3 Shift Complaint Test | Symptom Isolation Procedures F Purpose: Measure the resistance of the Input Shaft Speed Sensor through the Transmission Harness. G Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground through the Transmission Harness. 1. Key off. 1. Measure resistance between the Transmission Harness 38-way connector Pin 7 and ground. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure the resistance between the Transmission Harness 38-way connector Pin 7 and Pin 8. Front View Transmission ECU Connector 29 37 13 14 35 30 31 32 33 OHMS 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 V COM A 22 36 Transmission Harness 38-way Connector OHMS Front View Transmission ECU Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 • If resistance is OL, go to Step H. 22 21 36 • If resistance is less than 10K ohm, go to Step I. Transmission Harness 38-way Connector • If resistance is 2K to 4.5K ohm, go to Step G. • If resistance is outside of range, go to Step I. H Purpose: Visually remove and inspect the Input Shaft Speed Sensor for contamination or damage. 1. Inspect Input Shaft Speed Sensor for contamination or damage. • If no problem found, replace the: - Medium-Duty Transmission Electronic Control Unit (TECU) - Heavy-Duty Transmission Electronic Control Unit (TECU) Go to Step V. • If problem found or you were sent here from Step H or I, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor Inspect the upper countershaft PTO gear for damage. Go to Step V. 310 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 I Symptom Isolation Procedures | AutoShift AS3 Shift Complaint Test Purpose: Measure the resistance of the Input Shaft Speed Sensor at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. J Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground at the Input Shaft Speed Sensor. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. OHMS A B OHMS A V B V COM A COM A GROUND • If resistance is 2K to 4.5K ohm, go to Step J. • If resistance is outside of range, go to Step H. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, go to Step H. 2016.01.15 © 2016 Eaton. All rights reserved 311 TRTS0930 AutoShift AS3 Shift Complaint Test | Symptom Isolation Procedures K Purpose: Measure vehicle air supply pressure. 1. Key off. 2. Install a 0-100 PSI air pressure gauge in the regulated test port of the air filter/regulator. M Purpose: Verify air filter/regulator operation. 1. Read air pressure gauge installed at the regulated port. • If air pressure is between 55 to 65 PSI, go to Step O. 3. Start engine and allow air pressure to build to governor cut-off. • If air pressure is outside of range, go to Step N. 4. Monitor the vehicle air pressure gauge on the dash. 0-100 PSI N Purpose: Confirm air flow to the filter regulator supply port. Regulated test port 1. Remove air supply line to the air filter/regulator and check airflow. L • If air pressure cuts off between 90 to 120 PSI, go to Step L. • If air flows from the supply line, repair Air Filter Regulator. Go to Step K. • If air pressure is outside of range, repair vehicle air system as required. Repeat test. • If air does not flow from the supply line, repair vehicle air supply to the regulator. Go to Step K. Purpose: Confirm vehicle maintains air supply pressure. 1. Key off. 2. Monitor the vehicle air pressure gauge on the dash. • If vehicle maintains air pressure, go to Step M. • If vehicle loses air pressure, repair vehicle air system as required. Repeat test. 312 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 O Symptom Isolation Procedures | AutoShift AS3 Shift Complaint Test Purpose: Measure low range air pressures. P Purpose: Measure high range air pressures. 1. Key off. 1. Key on. 2. Install both 0-100 PSI air pressure gauges into the range cover diagnostic ports. 2. With the Shift Control, select the highest reverse gear available by pressing the upshift button/arrow, then select neutral. 3. Start vehicle and allow air pressure to build to governor cut-off. HI range 0-100 PSI gauge 4. Turn off engine, but leave key on. 5. With Shift Control, select reverse, then select neutral. LO range 0-100 PSI gauge Note: Five minutes is allowed for checking the air pressure after shifting the transmission to neutral. HI range 0-100 PSI gauge LO range 0-100 PSI gauge • If high range gauge is between 55 to 65 PSI and if low range gauge is 0 PSI, go to Step Q. • If both air pressure gauges do not read as listed above, replace Range Valve. Go to Step V. • If low range gauge is between 55 to 65 PSI and If high range gauge is 0 PSI, go to Step P. • If both air pressure gauges do not read as listed above, replace Range Valve. Go to Step P. Q Purpose: Identify if the transmission is equipped with a splitter system. 1. Is the transmission equipped with a splitter system? (i.e. 18-Speed) • If the transmission is equipped with a splitter system, go to Step R. • If the transmission is not equipped with a splitter system, go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 313 TRTS0930 AutoShift AS3 Shift Complaint Test | Symptom Isolation Procedures R Purpose: Measure high splitter air pressures. S Purpose: Measure low splitter air pressures. 1. Key off. 1. Key on. 2. Start vehicle and allow air pressure to build to governor cut-off. 2. With Shift Control, select reverse (R2 in the gear display 13/18-speed). 3. Turn off engine, but leave key on. 4. With Shift Control, select reverse (R1 in gear display for 13/18-speed), then select neutral Note: Five minutes is allowed for checking the pressure after moving the Shift Lever to neutral. Note: If R2 isn’t displayed the up arrow button needs to be pressed. HIGH split 0-100 PSI gauge LOW split 0-100 PSI gauge LO split 0-100 PSI gauge HI split 0-100 PSI gauge • If low splitter gauge is between 55 to 65 PSI and if high splitter gauge is 0 PSI, go to Step V. • If high splitter gauge is between 55 to 65 PSI and if low splitter gauge is 0 PSI, go to Step S. • If air pressure gauges do not read as shown above, replace Splitter Valve. Go to Step V. • If air pressure gauges do not read as shown above, replace Splitter Valve. Go to Step V. 314 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Symptom Isolation Procedures | AutoShift AS3 Shift Complaint Test Purpose: Verify repair. 1. Key off. 2. Remove all pressure gauges. 3. Reconnect all connectors. 4. Key on. 5. Drive the vehicle to determine whether the complaint has been repaired. • If the transmission shifts normal, test complete. • If the transmission still has a shifting complaint, find error in testing. Go to Step A. 2016.01.15 © 2016 Eaton. All rights reserved 315 UltraShift DM3 Shift Complaint Test | Symptom Isolation Procedures TRTS0930 UltraShift DM3 Shift Complaint Test Overview This symptom-driven test is performed if a shift complaint exists, and there are no Active or Inactive codes. Detection There is no detection other than a driver complaint. Fallback There is no fallback mode for shift complaint; however, it may effect vehicle performance. Possible Causes This symptom can be caused by any of the following: 316 • Inertia Brake • Input Shaft Speed Sensor • Transmission Electric Control Unit (TECU) • Transmission Harness • Range System • Splitter System © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | UltraShift DM3 Shift Complaint Test Component Identification Input Shaft Speed Sensor Range System Splitter System Transmission Harness Transmission ECU ! Warning: Do not load test at the Diagnostic Port. 2016.01.15 © 2016 Eaton. All rights reserved 317 TRTS0930 UltraShift DM3 Shift Complaint Test | Symptom Isolation Procedures UltraShift DM3 Shift Complaint Test A Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. B Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. 1. Key off. 1. Locate diagnostic port on Transmission Harness. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 2. Key on. 3. Measure voltage between Pin C and the battery negative post. 3. Measure voltage across batteries. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port VOLTS VOLTS – + B A C D V COM A Battery Negative Post V COM A – + 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required and go to Step B. B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is 0.70 volts or less, go to Step C. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. 318 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | UltraShift DM3 Shift Complaint Test Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. D Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Key on. 2. Key on. 2. Measure voltage between Pin A and Pin C. 3. Measure voltage between Pin B and Pin C. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D B A C D 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is within 0.6 volts of battery voltage, go to Step D. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. E Purpose: Monitor Engine Speed and Input Shaft Speed in ServiceRanger. 1. Compare engine RPM to Input Shaft RPM with ServiceRanger. Note: Engine RPM must remain above 1000 RPM during the following test. • If Input Shaft speed matches engine RPM, go to Step K. • If Input shaft speed reads 0, go to Step F. 2016.01.15 © 2016 Eaton. All rights reserved 319 TRTS0930 UltraShift DM3 Shift Complaint Test | Symptom Isolation Procedures F Purpose: Measure the resistance of the Input Shaft Speed Sensor through the Transmission Harness. 1. Key off. H Purpose: Visually remove and inspect the Input Shaft Speed Sensor for contamination or damage. 1. Inspect Input Shaft Speed Sensor for contamination or damage. 2. Disconnect negative battery cable. • If no problem found, replace TECU and go to Step V. 3. Disconnect the Transmission Harness 38-way connector. • If problem found or you were sent here from Step I or Step J, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor 4. Measure the resistance between the Transmission Harness 38-way connector Pin 7 and Pin 8. OHMS Inspect the upper countershaft PTO gear for damage. Go to Step V. Front View Transmission ECU Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 21 22 36 Transmission Harness 38-way Connector • If resistance is 2K to 4.5K ohm, go to Step G. • If resistance is outside of range, go to Step I. I Purpose: Measure the resistance of the Input Shaft Speed Sensor at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. G Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground through the Transmission Harness. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. 1. Measure resistance between the Transmission Harness 38-way connector Pin 7 and ground. OHMS A B V COM A • If resistance is OL, go to Step H. • If resistance is less than 10K ohm, go to Step I. • If resistance is 2K to 4.5K ohm, go to Step J. • If resistance is outside of range, go to Step H. 320 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 J Symptom Isolation Procedures | UltraShift DM3 Shift Complaint Test Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground at the Input Shaft Speed Sensor. K Purpose: Measure vehicle air supply pressure. 1. Key off. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. OHMS A 3. Start engine and allow air pressure to build to governor cut-off. B V COM 2. Install a 0-100 PSI air pressure gauge in the regulated test port of the air filter/regulator. A 4. Monitor the vehicle air pressure gauge on the dash. GROUND 0-100 PSI • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, go to Step H. Regulated test port • If air pressure cuts off at 90 to 120 PSI, go to Step L. • If air pressure is outside of range, repair vehicle air system as required. Repeat test. L Purpose: Confirm vehicle maintains air supply pressure. 1. Key off. 2. Monitor the vehicle air pressure gauge on the dash. • If vehicle maintains air pressure, go to Step M. • If vehicle loses air pressure, repair vehicle air system as required. Repeat test. 2016.01.15 © 2016 Eaton. All rights reserved 321 TRTS0930 UltraShift DM3 Shift Complaint Test | Symptom Isolation Procedures M Purpose: Verify air filter/regulator operation. O 1. Read air pressure gauge installed at the regulated port. Purpose: Measure low range air pressures. 1. Key off. • If air pressure is 55 to 65 PSI, go to Step O. 2. Install both 0-100 PSI air pressure gauges into the range cover diagnostic ports. • If air pressure is outside of range, go to Step N. 3. Start vehicle. Allow air pressure to build to governor cut-off. 4. Turn off engine, but leave key on. 5. With Shift Control, select reverse, then select neutral. N Purpose: Confirm air flow to the filter regulator supply port. 1. Remove air supply line to the air filter/regulator and check airflow. Note: Five minutes is allowed for checking the air pressure after shifting the transmission to neutral. HI range 0-100 PSI gauge LO range 0-100 PSI gauge • If air flows from the supply line, repair the Air Filter Regulator. • If air does not flow from the supply line, repair vehicle air supply to the regulator and go to Step J. • If low range gauge reads 55 to 65 PSI and high range gauge reads 0 PSI, go to Step C. • If neither gauge reads as listed above, replace the Range Valve. Go to Step V. 322 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 P Symptom Isolation Procedures | UltraShift DM3 Shift Complaint Test Purpose: Measure high range air pressures. R Purpose: Measure high splitter air pressures. 1. Key on. 1. Key off. 2. With the Shift Control, select the highest reverse gear available by pressing the upshift button/arrow, then select neutral. 2. Start vehicle and allow air pressure to build to governor cut-off. HI range 0-100 PSI gauge LO range 0-100 PSI gauge 3. Turn off engine, but leave key on. 4. With Shift Control, select reverse (R1 in gear display for 13/18-speed), then select neutral. Note: Five minutes is allowed for checking the pressure after moving the Shift Lever to neutral. LO split 0-100 PSI gauge HI split 0-100 PSI gauge • If high range gauge reads 55 to 65 PSI and low range gauge is 0 PSI, go to Step Q. • If neither gauge reads as listed above, replace the Range Valve. Go to Step V. • If high splitter gauge reads 55 to 65 PSI and low splitter gauge is 0 PSI, go to Step S. • If air pressure gauges do not read as shown above, replace Splitter Valve. Go to Step V. Q Purpose: Identify if the transmission is equipped with a splitter system. 1. Is the transmission equipped with a splitter system? (i.e. 13-Speed) • If the transmission is equipped with a splitter system, go to Step R. • If the transmission is not equipped with a splitter system, go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 323 TRTS0930 UltraShift DM3 Shift Complaint Test | Symptom Isolation Procedures S Purpose: Measure low splitter air pressures. V Purpose: Verify repair. 1. Key on. 1. Key off. 2. With Shift Control, select reverse (R2 in the gear display 13/18-speed). 2. Remove all pressure gauges. Note: If R2 isn’t displayed the up arrow button needs to be pressed. 3. Reconnect all connectors. 4. Key on. 5. Drive the vehicle to determine whether the complaint has been repaired. HIGH split 0-100 PSI gauge LOW split 0-100 PSI gauge • If the transmission shifts normal, test complete. • If the transmission still has a shifting complaint go to Step A. to find error in testing. • If low splitter gauge reads 55 to 65 PSI and if high splitter gauge is 0 PSI, go to Step V. • If neither gauge reads as shown above, replace the Splitter Valve. Go to Step V. 324 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 2016.01.15 Symptom Isolation Procedures | UltraShift DM3 Shift Complaint Test © 2016 Eaton. All rights reserved 325 UltraShift AW3 Shift Complaint Test | Symptom Isolation Procedures TRTS0930 UltraShift AW3 Shift Complaint Test Overview This symptom-driven test is performed if a shift complaint exists, and there are no Active or Inactive codes. Detection There is no detection other than a driver complaint. Fallback There is no fallback mode for shift complaint; however, it may effect vehicle performance. Possible Causes This symptom can be caused by any of the following: 326 • Low Fluid Level • Inertia Brake • Input Shaft Speed Sensor • Transmission Electronic Control Unit (TECU) • Transmission Harness © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | UltraShift AW3 Shift Complaint Test Component Identification Transmission Harness Transmission ECU Inertia Brake 2016.01.15 © 2016 Eaton. All rights reserved 327 TRTS0930 UltraShift AW3 Shift Complaint Test | Symptom Isolation Procedures UltraShift AW3 Shift Complaint Test A Purpose: Inspect the transmission fluid level. B Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground supplies at the batteries. 1. Place transmission in neutral. 2. Allow engine to idle at 600 to 700 RPM for a minimum of 2 minutes. Ensure transmission fluid temperature is 60 to 120 degrees F (16 to 49 degrees C) 1. Key off. 2. Inspect starter/battery and in-line fuse holder connections for integrity. 3. Measure voltage across batteries. 3. Check transmission fluid level. • If fluid level is at cold-full mark, go to Step B. VOLTS • If fluid level is below the cold-add mark, correct fluid level, check for leaks and go to Step V. V COM – + – + A • If voltage is 11 to 13 volts on a 12-volt system or 22 to 26 on a 24-volt system, proceed with battery load test. Repair or replace batteries as required and go to Step C. • If voltage is outside of range, repair or replace batteries and charging system as required. Repeat test. 328 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | UltraShift AW3 Shift Complaint Test Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diagnostic connector. D Purpose: Measure proper battery voltage at the transmission harness 4-way diagnostic connector. 1. Locate diagnostic port on Transmission Harness. 1. Locate diagnostic port on Transmission Harness. 2. Key on. 2. Key on. 3. Measure voltage between Pin B and Pin C. 3. Measure voltage between Pin C and the battery negative post. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port B A C D VOLTS B A C D V COM A Battery Negative Post 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + • If voltage between Pin C and battery negative post is 0.70 volts or less, go to Step D. • If voltage is outside of range, repair battery ground supply to TECU. Repeat test. 2016.01.15 B - Service Bat. + C - Service Bat. A - Service Ignition + © 2016 Eaton. All rights reserved • If voltage is within 0.6 volts of battery voltage, go to Step E. • If voltage is outside of range, repair battery power supply to TECU. Fuse may be blown. Repeat test. 329 TRTS0930 UltraShift AW3 Shift Complaint Test | Symptom Isolation Procedures E Purpose: Measure proper ignition voltage at the transmission harness 4-way diagnostic connector. F Purpose: Perform “Inertia Brake Test” using ServiceRanger. 1. Key on. 1. Key on. 2. Measure voltage between Pin A and Pin C. 2. Connect ServiceRanger, select Advanced Product Function. Warning! - Do Not Load Test at Diagnostic Port 4-Pin Diagnostics Port 3. Start engine, PTO must be disengaged. 4. Select Inertia Brake test. B A C D 5. Run test and follow instructions. • Test passes, go to Step G. • Test fails, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor 4-way 4-Pin Diagnostic Port (Located at the left rear corner of the transmission.) B - Service Bat. + C - Service Bat. A - Service Ignition + Go to Step V. • Test aborts, correct displayed test failure condition and retest. • If voltage is within 0.6 volts of battery voltage, go to Step F. • If voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test. G Purpose: Monitor Engine Speed and Input Shaft Speed in ServiceRanger. 1. Drive vehicle and monitor engine RPM and input shaft RPM with ServiceRanger • If engine RPM and input shaft rpm match during the test drive, test complete. • If input shaft RPM is erratic or reads zero, go to Step H. 330 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 H Symptom Isolation Procedures | UltraShift AW3 Shift Complaint Test Purpose: Measure the resistance of the Input Shaft Speed Sensor through the Transmission Harness. I Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground through the Transmission Harness. 1. Key off. 1. Measure resistance between the Transmission Harness 38-way connector Pin 7 and ground. 2. Disconnect negative battery cable. 3. Disconnect the Transmission Harness 38-way connector. 4. Measure the resistance between the Transmission Harness 38-way connector Pin 7 and Pin 8. Front View Transmission ECU Connector 29 37 13 14 35 30 31 32 33 OHMS 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 V COM A 22 36 Transmission Harness 38-way Connector OHMS Front View Transmission ECU Connector V 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 COM A 38 21 • If resistance is OL, go to Step J. 22 36 Transmission Harness 38-way Connector • If resistance is less than 10K ohm, go to Step K. • If resistance is 2K to 4.5K ohm, go to Step I. • If resistance is outside of range, go to Step J. J Purpose: Visually remove and inspect the Input Shaft Speed Sensor for contamination or damage. 1. Inspect Input Shaft Speed Sensor for contamination or damage. • If no problem found, replace TECU go to Step V. • If problem found or you were sent here from Step J or K, replace the: - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor Inspect the upper countershaft PTO gear for damage. Go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 331 TRTS0930 UltraShift AW3 Shift Complaint Test | Symptom Isolation Procedures K Purpose: Measure the resistance of the Input Shaft Speed Sensor at the Input Shaft Speed Sensor. 1. Disconnect the Transmission Harness from the Input Shaft Speed Sensor. 2. Measure resistance between Input Shaft Speed Sensor Pin A and Pin B. L Purpose: Test the Input Shaft Speed Sensor circuit for a short to ground at the Input Shaft Speed Sensor. 1. Measure resistance between Input Shaft Speed Sensor Pin A and ground. OHMS A B OHMS A V B V COM A COM A GROUND • If resistance is 2K to 4.5K ohm, go to Step L. • If resistance is outside of range, go to Step J. • If resistance is OL, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. • If resistance is less than 10K ohm, go to Step J. 332 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 V Symptom Isolation Procedures | UltraShift AW3 Shift Complaint Test Purpose: Verify repair. 1. Key off. 2. Reconnect all connectors. 3. Key on. 4. Drive the vehicle to determine whether the complaint has been repaired. • If the transmission shifts normal, test complete. • If the transmission still has a shifting complaint go to Step A. to find error in testing. 2016.01.15 © 2016 Eaton. All rights reserved 333 Shift Lever Back Light Test | Symptom Isolation Procedures TRTS0930 Shift Lever Back Light Test Overview This symptom-driven test is performed if the Shift Lever or Shift Control back lighting is not functioning. Detection There is no detection other than a driver complaint. Fallback There is no fallback mode for this symptom. Possible Causes This symptom can be caused by any of the following: 334 • OEM Wiring • Shift Control • Shift Lever © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Symptom Isolation Procedures | Shift Lever Back Light Test Component Identification Push Button Shift Control 3 4 1 8 2 3 4 1 8 2 6 5 7 6 5 7 Dimmer control input Back side of gauges Dash lights Push Button Control 30-way connector F2 F1 J3 25 31 15 16 17 23 C1 B3 Back side Dimmer control input of gauges Dash lights Shift Control ECU Legend All OEM responsible wiring shown is "typical". Consult specific application. (4-31, C1) = +12 volt switched from TECU (1-15, 8-16, 2-17, F2, F1) = Communication from and to the ECU15.8.2 (3-25, 5, J3, B3) = Signal returns, grounds, and general OEM wiring (6-23) = Signal from ECU 2016.01.15 © 2016 Eaton. All rights reserved 335 TRTS0930 Shift Lever Back Light Test | Symptom Isolation Procedures Shift Lever Back Light Test A Purpose: Visually identify the Driver Interface Device. 1. Verify Shift Lever. B Purpose: Measure the dimmer switch voltage supply to the Shift Control. 1. Key off. • If vehicle is equipped with an OEM Shift Lever, refer to OEM for repair strategy. • If vehicle is equipped with a Push Button Shift Control, go to Step B. • If vehicle is equipped with Cobra Lever, go to Step C. 2. Disconnect Shift Control 30-way connector. 3. Key on. 4. Turn dimmer switch to max. 5. Measure voltage between Pin B3 and Pin J3. VOLTS V COM 3 2 1 3 2 1 A K J H G F E D C B A • If voltage is within 0.6 volts of battery voltage, replace Shift Control. Go to Step V. • If voltage is outside of range, repair OEM wire between Pin B3 and the dash lights and go to Step V. 336 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 C Symptom Isolation Procedures | Shift Lever Back Light Test Purpose: Inspect Cobra Lever lights with dimmer switched turned to the max position. D Purpose: Measure the dimmer switch voltage supply to the Cobra Lever. 1. Key on. 1. Key off. 2. Turn vehicle lights on. 2. Disconnect Cobra Lever 8-way connector. 3. Turn dimmer switch to max. 3. Key on. • Cobra Lever lights on, but do not dim when vehicle lights are on, go to Step D. • Cobra Lever lights do not come on, go to Step E. 4. Turn dimmer switch to max. 5. Measure voltage between Pin 5 and Pin 3 on the 8-way Vehicle Harness. VOLTS V COM A 1 8 2 7 3 6 4 5 • If voltage is within 2 volts of battery voltage, replace Cobra Lever and go to Step V. • If voltage is outside of range, repair OEM wire between Pin 5 and dash lights and go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 337 TRTS0930 Shift Lever Back Light Test | Symptom Isolation Procedures E Purpose: Measure the ignition voltage supply to the Cobra Lever. F Purpose: Verify continuity of the power supply from the TECU to the Cobra Lever and test for a short to ground. 1. Key off. 1. Key off. 2. Disconnect Cobra Lever 8-way connector. 2. Disconnect Negative battery cable. 3. Key on. 4. Measure voltage between Pin 3 and Pin 4 on the 8-way Vehicle Harness connector. VOLTS V COM A 3. Disconnect Vehicle Harness 38-way connector. 4. Measure resistance between: - Vehicle Harness 38-way connector Pin 31 and Vehicle Harness 8-way connector Pin 4. - Vehicle Harness 38-way connector Pin 31 and ground. OHMS 1 8 2 7 3 6 4 5 V 1 8 2 3 7 6 4 5 COM Front View 38-Way Connector A 37 13 14 35 31 29 30 23 24 25 26 27 28 15 16 17 18 19 20 8 9 10 11 12 2 3 4 5 6 31 32 33 34 7 1 32 33 34 38 22 21 36 OHMS V COM A 37 13 14 35 29 30 23 24 25 26 27 28 15 16 17 18 19 20 8 9 10 11 12 2 3 4 5 6 7 1 38 22 21 36 Vehicle Harness 38-way Connector • If voltage is within 0.6 volts of battery voltage, replace Cobra Lever. Go to Step V. • If resistance between Pin 31 and Pin 4 is 0 to 0.3 ohms and the resistance between Pin 31 and ground is OL, go to Step G. • If voltage is out of range, go to Step F. • If any of the above conditions are not met, replace the: - Medium-Duty Transmission Harness - Heavy-Duty Transmission Harness Go to Step V. 338 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 G Symptom Isolation Procedures | Shift Lever Back Light Test Purpose: Verify continuity of the ground supply from the TECU to the Cobra Lever and test for a short to ground. V Purpose: Verify repair. 1. Key off. 1. Key off. 2. Reconnect all connectors. 2. Measure resistance between Vehicle Harness 38-way connector Pin 25 and Vehicle Harness 8-way connector Pin 3 Vehicle Harness 38-way connector Pin 25 and ground. 3. Key on. 4. Turn on the dash lights fully. • If back light works correctly, test complete. OHMS V 1 8 2 3 7 6 4 5 COM Front View 38-Way Connector A 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 31 32 • If back lights do not work correctly, go to Step A. to find error in testing. 38 22 21 36 OHMS V COM A 37 13 14 35 29 30 33 34 23 24 25 26 27 28 15 16 17 18 19 20 8 9 10 11 12 2 3 4 5 6 7 1 38 22 21 36 Vehicle Harness 38-way Connector • If resistance between Pin 25 and Pin 3 is 0 to 0.3 ohms and the resistance between Pin 25 and ground is OL, see “Electrical Pretest” on page 12. If test passes, replace the - Medium-Duty Input Shaft Speed Sensor - Heavy-Duty Input Shaft Speed Sensor go to Step V. 2016.01.15 © 2016 Eaton. All rights reserved 339 TRTS0930 Connector Pin Descriptions | Appendix Connector Pin Descriptions Transmission Controller 38-Way (Vehicle Interface Connector) 38-Way Description Wire 38-Way Description Wire 1 J1939 Shield (CAN) 18 TXL 20 MEIIR Contact 18 TXL 2 J1939 Low (CAN) 18 TXL 21 MEIIR Minus 18 TXL 3 J1939 High (CAN) 18 TXL 22 MEIIR Plus 18 TXL 4 Start Enable Relay Minus 18 TXL 23 Service Light Output 18 TXL 5 Not Used Plug 24 Not Used 18 TXL 6 Not Used Plug 25 Shift Control Power Minus 18 TXL 7 Not Used Plug 26 Start Enable Latch 18 TXL 8 Not Used Plug 27 HIL Low (Proprietary CAN) 18 TXL 9 Not Used Plug 28 HIL High (Proprietary CAN) 18 TXL 10 J1587 Plus 18 TXL 29 Not Used Plug 11 J1587 Minus 18 TXL 30 Not Used Plug 12 ISO9141-K Communications 18 TXL 31 Shift Control Power Plus 18 TXL 13 Not Used Plug 32 Start Enable Relay Plus 18 TXL 14 Not Used Plug 33 Not Used Plug 15 Shift Control Input (Mode Auto) 18 TXL 34 Not Used Plug 16 Shift Control Input (Mode Manual/Neutral Signal) 18 TXL 35 Ignition 12 GXL or 14SXL 17 Shift Control Input (Mode Common/Neutral Return) 18 TXL 36 Battery Minus 12 GXL 18 PTO 18 TXL 37 Not Used Plug 19 Auto Neutral AW3 18 TXL 38 Battery Plus 12 GXL 340 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Connector Pin Descriptions Push Button Shift Control 30-Way Connector Cobra Lever 8-Way Connector 8-Way Description Wire 1 Shift Control Input (Mode Auto) 16 TXL 30-Way Description Wire 2 Shift Control Input (Mode Common) 16 TXL C1 Shift Control Power Plus 16 TXL 3 Shift Control Power Minus 16 TXL B3 V Dash 16 TXL 4 Shift Control Lever Power Plus 16 TXL F1 HIL(+) HI 16 TXL 5 Dash Lights 16 TXL F2 HIL(-) LO 16 TXL 6 Service Light Output 16 TXL 7 No Connection 16 TXL J3 Shift Control Power Minus 16 TXL 8 Shift Control Input (Mode Manual) 16 TXL 2016.01.15 © 2016 Eaton. All rights reserved 341 TRTS0930 Connector Pin Descriptions | Appendix Transmission Controller 38-Way (Eaton Supplied Assembly) 38-Way Description Wire 38-Way Description Wire 1 Not Used Plug 20 Rail Position Sensor Minus 18 TXL 2 Clutch Lube Solenoid Plus 18 TXL 21 Not Used Plug 3 Clutch Lube Solenoid Minus 18 TXL 22 Not Used Plug 4 Splitter Solenoid Common Minus 18 TXL 23 Output Shaft Speed Sensor High 18 TXL 5 Inertia Brake Solenoid Minus 18 TXL 24 Output Shaft Speed Sensor Low 18 TXL 6 Range Solenoid Common Minus 18 TXL 25 Service Ignition 18 TXL 7 Input Shaft Speed Sensor High 18 TXL 26 Splitter Indirect Solenoid Plus 18 TXL 8 Input Shaft Speed Sensor Low 18 TXL 27 Not Used Plug 9 Not Used Plug 28 Range High Solenoid Plus 18 TXL 10 Gear Position Sensor Plus 18 TXL 29 Not Used 18 TXL 11 Gear Position Sensor Signal 18 TXL 30 Not Used 18 TXL 12 Gear Position Sensor Minus 18 TXL 31 Service Battery Minus 18 TXL 13 Clutch Solenoid Plus 18 TXL 32 Splitter Direct Solenoid Plus 18 TXL 14 Clutch Solenoid Minus 18 TXL 33 Inertia Brake Solenoid Plus 18 TXL 15 Main Shaft Speed Sensor High 18 TXL 34 Range Low Solenoid Plus 18 TXL 16 Main Shaft Speed Sensor Low 18 TXL 35 Rail Motor Plus 14SXL 17 Service Battery Plus 18 TXL 36 Gear Motor Plus 14SXL 18 Rail Position Sensor Plus 18 TXL 37 Rail Motor Minus 14SXL 19 Rail Position Sensor Signal 18 TXL 38 Gear Motor Minus 14SXL 342 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams Wiring Diagrams UltraShift DM3 6-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM For Transmission Diagnostics 18 19 20 10 11 12 B A C D Rail select sensor A B C Gear select sensor A B C 7 8 38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1 Terminating resistor A B Input shaft speed sensor 23 24 A B Vehicle Interface Legend Output shaft speed sensor B C A 4-way 17 31 25 33 5 A B B - Service Bat. + C - Service Bat. A - Service Ignition + Inertia brake All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU (20) = Signal into the TECU Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 343 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 6 5 7 6 5 7 For Transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges Dash lights 10 AMP 12 volt only manual resetting circuit breaker 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 or D E J-1939 High F C A Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse J-1939 Low +12 volts battery B J G H C D B F G A J-1587 data link 9-way Run to starter solenoid 30 Bulkhead connector located at firewall Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or J-1939/11 data link (OEM supplied) + _ Shield termination 30 87 86 85 Start enable relay Vehicle Interface Legend Engine ECM 10 AMP fuse Run to start signal from igntion switch All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU (20-87) = Signal into TECU Terminating resistor GND 344 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift DM3 6-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM For Transmission Diagnostics 18 19 20 10 11 12 B A C D Rail select sensor A B C Gear select sensor A B C 7 8 Terminating resistor A B Input shaft speed sensor 23 24 A Vehcile Interface Legend B All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (20) = Signal into the TECU Output shaft speed sensor B C A 4-way 17 31 25 33 5 B - Service Bat. + C - Service Bat. A - Service Ignition + A B Inertia brake Gear select motor 36 38 35 37 Rail select motor 2016.01.15 38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1 Electric shifter © 2016 Eaton. All rights reserved 345 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 B3 Dimmer control input For Transmission Diagnostics per SAE Standard Back side of gauges Dash lights J-1939 High 10 AMP 12 volt only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20 or Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or 10 AMP fuse C A J-1939 Low +12 volts battery B J G 30 Bulkhead connector located at firewall D E F H C D B F G A J-1587 data link 9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85 Start enable relay Vehicle Interface Legend Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU (20-87) = Signal into TECU J-1939/11 data link (OEM supplied) + _ Shield termination Terminating resistor GND 346 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift AW3 6-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1 Rail select sensor A B C Gear select sensor A B C 7 8 A B Input shaft speed sensor For Transmission Diagnostics 23 24 A Terminating resistor B Output shaft speed sensor B A C D Vehicle Interface Legend 33 5 B C A 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + A B Inertia brake 17 31 25 2 3 13 14 All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU Hydraulic manifold Assembly Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 347 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 Dimmer control input 6 5 7 6 5 7 Transmission ECU Connector Pins 25 31 15 16 17 23 35 10 11 26 32 4 J-1939 High Back side of gauges Dash lights 10 AMP 12 volt only manual resetting circuit breaker or 10 AMP fuse For transmission Diagnostics per SAE Standard F Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) D E J-1939 Low C A B J G +12 volts Battery H C D B F G A J-1587 data link 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Vehicle Interface Legend Engine ECM J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Terminating resistor All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU GND 348 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift AW3 6-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery Bulkhead connector located at firewall OEM 18 19 20 10 11 12 B C A C D Gear select sensor A B C A B Input shaft speed sensor 23 24 B Rail select sensor A 7 8 For Transmission Diagnostics 38 36 27 28 25 31 35 10 11 26 32 4 3 2 1 A Terminating resistor B Output shaft speed sensor Vehicle Interface Legend 33 5 B C A 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + A B 17 31 25 Inertia brake All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU 2 3 13 14 Hydraulic manifold Assembly Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 349 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 For transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges B3 J-1939 High 10 AMP 12 volt only manual resetting or 10 AMP circuit breaker fuse 27 28 25 31 35 10 11 26 32 4 Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) C A B J G J-1939 Low +12 volts Battery D E F Transmission ECU Connector Pins H F C D B F G A J-1587 data link 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Vehicle Interface Legend Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Terminating resistor GND 350 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams AutoShift 10-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C C A B 15 16 A C D Input shaft speed sensor A B 23 24 B A B Vehicle Interface Legend Main shaft speed sensor Output shaft speed sensor 6 34 28 B C A Terminating resistor Gear select sensor B 7 8 For Transmission Diagnostics Rail select sensor A A 38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1 C B A 17 31 25 Range valve All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 351 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 Dimmer control input 6 5 7 6 5 7 25 31 15 16 17 23 35 10 11 26 32 4 J-1939 High Back side of gauges Dash lights Transmission ECU Connector Pins 10 AMP 12 volt only manual resetting circuit breaker or For transmission Diagnostics per SAE Standard F Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse D E J-1939 Low C A B J G +12 volts Battery H C D B F G A J-1587 data link 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Vehicle Interface Legend Engine ECM J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Terminating resistor All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU GND 352 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams AutoShift 10-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C C A C D B 15 16 Input shaft speed sensor A B A B Vehicle Interface Legend Main shaft speed sensor Output shaft speed sensor 6 34 28 B C A Terminating resistor A 23 24 B Gear select sensor B 7 8 For Transmission Diagnostics Rail select sensor A A 38 36 27 28 25 31 35 10 11 26 32 4 3 2 1 C B A Range valve All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU 17 31 25 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 353 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 For transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges B3 J-1939 High Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP 12 volt only manual resetting or 10 AMP circuit breaker fuse 27 28 25 31 35 10 11 26 32 4 C A B J G J-1939 Low +12 volts Battery D E F Transmission ECU Connector Pins H F C D B F G A J-1587 data link 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Vehicle Interface Legend Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Terminating resistor GND 354 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift 10-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C A C D Gear select sensor A B C A B 15 16 Input shaft speed sensor A B 23 24 B Rail select sensor A 7 8 For Transmission Diagnostics 38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1 A B Terminating resistor Main shaft speed sensor Output shaft speed sensor Vehicle Interface Legend 6 34 28 B C A C B A Range valve 17 31 25 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + 33 5 A All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35)= +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU (20) = Signal into the TECU B Inertia brake (Optional) Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 355 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 6 5 7 6 5 7 For Transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges Dash lights 10 AMP 12 volt only manual resetting circuit breaker 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 or D E J-1939 High F C A Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse J-1939 Low +12 volts battery B J G H C D B F G A J-1587 data link 9-way Run to starter solenoid 30 Bulkhead connector located at firewall Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or J-1939/11 data link (OEM supplied) + _ Shield termination 30 87 86 85 Start enable relay Vehicle Interface Legend Engine ECM 10 AMP fuse Run to start signal from igntion switch All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU (20-87) = Signal into TECU Terminating resistor GND 356 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift 10-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C A C D Gear select sensor A B C A B 15 16 Input shaft speed sensor A B 23 24 B Rail select sensor A 7 8 For Transmission Diagnostics 38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1 A B Terminating resistor Main shaft speed sensor Output shaft speed sensor Vehicle Interface Legend 6 34 28 B C A 4-way C B A Range valve 17 31 25 33 5 A B B - Service Bat. + C - Service Bat. A - Service Ignition + All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (20) = Signal into the TECU Inertia brake (Optional) Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 357 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 B3 Dimmer control input For Transmission Diagnostics per SAE Standard Back side of gauges Dash lights J-1939 High 10 AMP 12 volt only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20 or Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or 10 AMP fuse C A J-1939 Low +12 volts battery B J G 30 Bulkhead connector located at firewall D E F H C D B F G A J-1587 data link 9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85 Start enable relay Vehicle Interface Legend Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU (20-87) = Signal into TECU J-1939/11 data link (OEM supplied) + _ Shield termination Terminating resistor GND 358 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift 13-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C Gear select sensor A B C 7 8 A B Input shaft speed sensor A B 23 24 Terminating resistor A B Main shaft speed sensor Output shaft speed sensor B C Rail select sensor A 15 16 For Transmission Diagnostics Vehicle Interface Legend A 6 34 28 C B A D 4 32 26 B C A 4-way 38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1 C B A Range valve Splitter valve 17 31 25 33 5 All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU (20) = Signal into the TECU Inertia brake A B B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 359 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 6 5 7 6 5 7 For Transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges Dash lights 10 AMP 12 volt only manual resetting circuit breaker 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 or D E J-1939 High F C A Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse J-1939 Low +12 volts battery B J G H F C D B F G A J-1587 data link 9-way Run to starter solenoid 30 Bulkhead connector located at firewall Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM Run to start signal from igntion switch 30 87 86 85 Start enable relay Vehicle Interface Legend Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or Engine ECM 10 AMP fuse All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a)= +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU (20-87) = Signal into TECU J-1939/11 data link (OEM supplied) + _ Shield termination Terminating resistor GND 360 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams UltraShift 13-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C Gear select sensor A B C A B 15 16 Input shaft speed sensor A B 23 24 A B Main shaft speed sensor Output shaft speed sensor B C 6 34 28 A Rail select sensor A 7 8 For Transmission Diagnostics C B A Range valve D 4 32 26 B C A 4-way 38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1 C B A Splitter valve 17 31 25 33 5 Terminating resistor Vehicle Interface Legend All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4, 21) = -12 volt relay source (22, 32) = +12 volt relay source (31) = +12 volt switched from TECU (20) = Signal into the TECU A B B - Service Bat. + C - Service Bat. A - Service Ignition + Inertia brake (Optional) Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 361 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 B3 Dimmer control input For Transmission Diagnostics per SAE Standard Back side of gauges Dash lights J-1939 High 10 AMP 12 volt only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20 or Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) 10 AMP fuse Ignition Interrupt relay 86 85 87 87a * Run to ignition input on Engine ECM J-1939 Low +12 volts battery B J H C D B F G A J-1587 data link 9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85 Start enable relay Vehicle Interface Legend Engine Power Relay Fused 10 AMP 12 volt manual resetting circuit breaker or 10 AMP fuse C A G 30 Bulkhead connector located at firewall D E F Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87, 87a) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85, 21-85) = -12 volt relay source (22-86, 32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU (20-87) = Signal into TECU J-1939/11 data link (OEM supplied) + _ Shield termination Terminating resistor GND 362 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams AutoShift 18-Speed Wiring Diagram with Analog Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C Gear select sensor A B C 7 8 A B Input shaft speed sensor A B 23 24 A C D B 6 34 28 Main shaft speed sensor C B A 4 32 26 B C A Terminating resistor A Output shaft speed sensor B Rail select sensor A 15 16 For Transmission Diagnostics 38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1 C B A 17 31 25 Range valve Splitter valve Vehicle Interface Legend All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (15, 16, 17, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU (23) = Signal from TECU 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 363 TRTS0930 Wiring Diagrams | Appendix 3 4 1 8 2 3 4 1 8 2 Dimmer control input 6 5 7 6 5 7 25 31 15 16 17 23 35 10 11 26 32 4 J-1939 High Back side of gauges Dash lights Transmission ECU Connector Pins 10 AMP 12 volt only manual resetting circuit breaker or For transmission Diagnostics per SAE Standard C A F 10 AMP fuse D E J-1939 Low Ignition Key Switch +12 volts Runs to main power lead that Battery feeds the ignition bus (OEM responsible for overcurrent protection on this line) J-1587 data link B J G H C D B F G A 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Engine ECM J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Vehicle Interface Legend All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (15-1, 16-8, 17-2, 10-F, 11-G) = Communication from and to the TECU (25-3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-4) = +12 volt switched from TECU (23-6) = Signal from TECU Terminating resistor GND 364 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams AutoShift 18-Speed Wiring Diagram with Push Button Shifter 30 AMP fuse Transmission ECU Battery power (Non-switched power) run to starter or Battery OEM 18 19 20 10 11 12 B C Gear select sensor A B C 7 8 A B Input shaft speed sensor A B 23 24 C Terminating resistor A B Main shaft speed sensor Output shaft speed sensor B Rail select sensor A 15 16 For Transmission Diagnostics 38 36 27 28 25 31 35 10 11 26 32 4 3 2 1 Vehicle Interface Legend A 6 34 28 D C B A 4 32 26 B C A C B A 17 31 25 Range valve Splitter valve All OEM responsible wiring shown is "typical". Consult specific application. (38) = +12 volt non-switched from battery (35) = +12 volt switched from ignition switch (26) = Latch into the ECU (27, 28, 10, 11, 3, 2, 1) = Communication from and to the TECU (36, 25) = Signal returns, grounds, and general OEM wiring (4) = -12 volt relay source (32) = +12 volt relay source (31) = +12 volt switched from TECU 4-way B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38 Gear select motor 2016.01.15 Electric shifter © 2016 Eaton. All rights reserved 365 TRTS0930 Wiring Diagrams | Appendix Push Button Shift Control Push Button Control 30-way connector F2 F1 J3 C1 For transmission Diagnostics per SAE Standard Dimmer control input Back side of gauges B3 J-1939 High 10 AMP 12 volt only manual resetting or 10 AMP circuit breaker fuse 27 28 25 31 35 10 11 26 32 4 D E F Transmission ECU Connector Pins C A J-1939 Low Ignition Key Switch Runs to main power lead that +12 volts feeds the ignition bus (OEM Battery responsible for overcurrent protection on this line) J-1587 data link B J G H C D B F G A 9-way Run to starter solenoid Bulkhead connector located at firewall Run to start signal from igntion switch 30 87 86 85 Vehicle InterfaceLegend Engine ECM All OEM responsible wiring shown is "typical". Consult specific application. (35, 30, 87) = +12 volt switched from ignition switch (26-87) = Latch into the ECU (27-F2, 28-F1, 10-F, 11-G) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring (4-85) = -12 volt relay source (32-86) = +12 volt relay source (31-C1) = +12 volt switched from TECU J-1939/11 data link (OEM supplied) + _ Shield termination Start enable relay Terminating resistor GND 366 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams Eaton Cobra Lever Wiring Diagram 3 4 1 8 2 3 4 1 8 2 C2 6 5 7 6 5 7 Transmission ECU Connector (Vehicle Interface) J1 Dimmer control input Back side of gauges Dash lights 25 31 15 16 17 23 Bulkhead connector located at firewall Trans Control ECU Legend All OEM responsible wiring shown is "typical". Consult specific application. (31-4) = +12 volt switched from TECU (15-1, 16-8, 17-2) = Communication from and to the TECU Front View (25-3, 5) = Signal returns, grounds, and general OEM wiring Transmission ECU Connector (23-6) = Signal from TECU 37 13 14 35 2016.01.15 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 FROM TO Description J1-15 C2-1 Shift Control Input (Mode Auto) J1-17 C2-2 Shift Control Input (Mode Common) J1-25 C2-3 Shift Control Power Minus J1-31 C2-4 Shift Control Power Plus C2-5 Dash Lights J1-23 C2-6 Service Light Output J1-16 C2-8 Shift Control Input (Mode Manual) C2-7 No Connection © 2016 Eaton. All rights reserved 38 21 22 36 367 TRTS0930 Wiring Diagrams | Appendix OEM Shift Lever Wiring Diagram OEM Shift Lever Transmission ECU Connector (Vehicle Interface) B A C B A C J1 15 16 17 23 Service Lamp Connector Vehicle Interface Legend All OEM responsible wiring shown is "typical". Consult specific application. (15-B, 16-A, 17-C) = Communication to and from the TECU (23) = Signal from TECU Front View Transmission ECU Connector 37 13 14 35 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 FROM TO Description J1-15 F2-B Shift Control Input (Mode Auto) J1-16 F2-A Shift Control Input (Mode Manual) J1-17 F2-C Shift Control Input (Mode Common) J1-23 F3-A Service Lamp Output F3-B 368 29 Ground © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams Eaton Push Button Wiring Diagram Push Button Shift Control Push Button Control 30-way connector C2 Transmission ECU Connector (Vehicle Interface) F2 F1 J3 C1 B3 Dimmer control input J1 27 28 25 31 Bulkhead connector located at firewall Front View Transmission ECU Connector (Vehicle Interface) 37 13 14 35 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 Front View Shift Control (30-Way Connector) 38 21 22 36 K1 J1 H1 G1 F1 E1 D1 C1 B1 A1 K2 J2 H2 G2 F2 E2 D2 C2 B2 A2 K3 J3 H3 G3 F3 E3 D3 C3 B3 A3 Vehicle Interface Legend All OEM responsible wiring shown is "typical". Consult specific application. (31-C1) = +12 volt switched from TECU (27-F2, 28-F1) = Communication from and to the TECU (25-J3) = Signal returns, grounds, and general OEM wiring FROM TO Description J1-27 C2-F2 HIL(-) LO J1-28 C2-F1 HIL(+) HI J1-25 C2-J3 Shift Control Power Minus J1-31 C2-C1 Shift Control Power Plus C2-B3 2016.01.15 Dimmer Control Input FROM TO Description J1-D1 C2-1 RNDHL J1-D3 C2-2 COMMON --------- C2-3 GROUND J1-J2 C2-4 SPLICE into TRANS BATT 1 © 2016 Eaton. All rights reserved 369 TRTS0930 Wiring Diagrams | Appendix FROM TO Description J1-B3 C2-5 DIMMER CONTROL J1-H2 C2-6 SERVICE LAMP J1-D2 C2-8 MANUAL MODE FROM TO Description J1-27 C2-F2 EPL- LO J1-28 C2-F1 EPL+ HI J1-25 C2-J3 Ground 1 J1-31 C2-C1 Ignition C2-B3 370 Dimmer Control Input © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Wiring Diagrams OEM J1939 Shift Input Device Wiring Diagram OEM J1939 Shift Device Transmission ECU Connector (Vehicle Interface) Bulkhead connector located at firewall J1 16 17 J1939 Battery Power (Non-switched power run to Battery or Starter) Ground Switched Power Front View Transmission ECU Connector (Vehicle Interface) 37 13 14 35 2016.01.15 29 30 31 32 33 34 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 1 2 3 4 5 6 38 21 22 36 FROM TO Description J1-16 Connector C2 Shift Control Input (Neutral Request Signal) J1-17 Connector C2 Shift Control Input (Neutral Request Return) OEM Connector C2 Shift Control Power Minus (Ground) OEM Connector C2 Shift Control Power Plus (Ignition) OEM Connector C2 Shift Control Power Plus (Battery) Connector C2 OEM J1939 High OEM Connector C2 J1939 Low OEM Connector C2 J1939 Shield © 2016 Eaton. All rights reserved 371 TRTS0930 Proper Clutch Operation | Appendix Proper Clutch Operation When performing the test for proper clutch operation, the vehicle should be in the same condition as when the problem occurred. For instance, if the problem only occurs when the vehicle is hot, drive the vehicle to warm it up before conducting the test. When the operator depresses the clutch pedal and shifts from neutral to drive or reverse, the Transmission Electronic Control Unit (TECU) waits for the transmission input shaft speed to decrease to less than 150 RPM before shifting the transmission into gear. If the clutch is not disengaging completely or the clutch brake is not functioning properly, the input shift will not slow down and the transmission will not shift into gear. 10. If clutch adjustment is correct and clutch brake appears satisfactory, the problem may be a defective clutch. The clutch may require repair or replacement. Refer to the clutch manufacturer’s service information to verify a dragging clutch. Without ServiceRanger a PC-based Service Tool 1. Place transmission in neutral. 2. Start engine. 3. Let up on the clutch pedal (clutch engaged). 4. Depress clutch pedal fully to activate clutch brake and hold for 2 seconds. 5. Place transmission in starting gear. Check For Proper Clutch Operation 6. If starting gear display shows a solid gear (engaged), the procedure is complete. If the gear display shows a flashing gear (not yet engaged) continue on to number 7. Note: Refer to publication CLSM0200. With PC-Base Service Tool 1. Connect ServiceRanger a PC-based Service Tool. 2. Make sure the transmission is in neutral 3. Start engine. 4. Set ServiceRanger a PC-based Service Tool to monitor input shaft speed. 5. With Clutch pedal up (clutch engaged), compare input shaft speed and engine speed (RPM). They should be the same. 7. If flashing gear is displayed, slowly release the clutch pedal. 8. If flashing gear does not become solid or gear does not engage, check clutch brake for proper function and check clutch adjustment. 9. If gear does not engage and clutch is adjusted properly, troubleshoot for a dragging clutch according to clutch manufacturer. Note: If engine speed and input shaft speeds are not the same, then perform input shaft speed sensor test and confirm proper clutch adjustment. 6. Check clutch for slippage, and repair or replace as needed. 7. Depress clutch pedal to active clutch brake. Within 2 seconds, input shaft speed should be less than 25 RPM (0 RPM is desired). If input shaft does not stop turning, the clutch is not disengaging completely or the clutch brake is not functioning properly. 8. Check for proper clutch adjustment, adjust as necessary. 9. Inspect clutch brake for excessive friction material wear or internal damage. Replace as necessary. Note: The clutch brake may have to be removed to inspect properly. 372 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Proper Clutch Operation Confirm Proper Clutch Adjustment and Clutch Brake Contact Confirm Release Bearing Travel Gap Use a 1/2” gauge to verify the release bearing travel gap. This gap (distance between the rear of the release bearing and the clutch brake) must be between 1/2” and 9/16”. If the 0.010” feeler gauge is not adequately squeezed to prevent removal, or can be removed with the pedal less than 1/2” or greater than 1”, check and adjust the clutch pedal height and travel per the chassis manufacturer’s instructions. In addition, check the external clutch linkage for excessive wear or obstruction preventing complete travel. If this dimension is incorrect, adjust the clutch per the clutch manufacturer’s instructions. Release yoke Confirm the Free-Play gap* *For mechanical clutch release systems with free-play. Use a 1/8” gauge to verify proper free-play gap on Easy Pedal. Clutch brake If this dimension is incorrect, adjust the clutch per the clutch manufacturer’s instructions. Confirm Proper Clutch Brake Contact Insert a 0.010” feeler gauge between the release bearing and the clutch brake have an assistant fully depress the clutch pedal. The 0.010” feeler gauge should be squeezed between the rear of the release bearing and the clutch brake. Have the assistant slowly let up the clutch pedal. The 0.010” feeler gauge should slide out when the clutch pedal is 1/2” to 1” above the cab floor or lower pedal stop. 2016.01.15 © 2016 Eaton. All rights reserved 1/8" 373 TRTS0930 Proper Clutch Operation | Appendix Clutch Grease Interval Service Procedure Clutch Greasing Guidelines It is highly important to follow proper clutch lube intervals as specified in Lubrication Manual, TCMT0021. Failure to do so may result in clutch failure and unnecessary repairs. For more detailed cross-shaft greasing information refer to the “Release Yoke and Cross-shaft(s) Installation” section of this manual. Refer to Clutch Service Manual, CLSM0200, for release bearing greasing information. 374 © 2016 Eaton. All rights reserved 2016.01.15 TRTS0930 Appendix | Adapter Test Kit J43318 Adapter Test Kit J43318 Note: Use extreme caution when inserting adapters into the connectors to avoid spreading or distorting of the terminals. Adapter Pins Use the male adapter to test the harness pins. Harness Gray Adapters Gray adapter are to only be used for the following connectors: • Shift Control 30-way connector • Speed Sensors • Position Sensors • Range Solenoid Valve • Splitter Solenoid Valve Green and Brown Adapters Green and brown adapters are to only be used for the following connectors: • Vehicle interface 38-way connector • Transmission Electronic Control Unit (TECU) 38-way connector Male adapters Use the female adapter to test the component pins. Female adapters Purple Adapters Purple adapter are to only be used for the following connectors: • Motors • Main Power • Inertia Brake 2016.01.15 © 2016 Eaton. All rights reserved Component 375 Copyright Eaton 2016. Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options. For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger. In Mexico, call 001-800-826-4357. Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road. Eaton Vehicle Group P.O. Box 4013 Kalamazoo, MI 49003 USA 800-826-HELP (4357) www.eaton.com/roadranger Printed in USA Eaton 1111 Superior Ave. Cleveland, OH 44114
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