Eaton Transmission APMT-1234 User Manual

Troubleshooting Guide

Eaton Gen III Automated Transmissions TRTS0930 EN-US

January 2016

Ult raShift ® 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

RTS0930 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 Fault Code 16 - High Integrity Link (HIL) Fault Code 17 - Start Enable Relay (SER

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

. . . . . .54

. . . . . . . . . . .62

) Circuit . . . . .70

Fault Code 31 - Momentary Engine Ignition Interrupt Re-

lay (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 Fault Code 85 - Shift Control Device Incompatible. . .256

Fault Code 99 - Direction Mismatch . . . . . . . . . . . . . .260

Device Not Configured .252

2016.01.15

Table of Contents

RTS0930

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

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

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

AutoShift 10-Speed Wiring

Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 353

UltraShift 10-Speed Wiring Diagram with Analog

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

UltraShift 10-Speed Wiring

Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 357

UltraShift 13-Speed Wiring Diagram with Analog

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

UltraShift 13-Speed Wiring

Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 361

AutoShift 18-Speed Wiring

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

AutoShift 18-Speed Wiring

Button Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Eaton Cobra Lever Wiring Diagram . . . . . . . . . . 367

Diagram with Analog

Diagram with Push

Diagram with Analog

Diagram with Push

OEM Shift Lever Wiring Diagram . . . . . . . . . . . . 368

Eaton Push Button Wiring Diagram . . . . . . . . . . 369

OEM J1939 Shift Input Device Wiring Diagram . 371

Proper Clutch Operation

Check For Proper Clutch Operation Confirm Proper Clutch Adjustment and Clutch

Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Clutch Grease Interval Service Procedure . . . . . 374

Adapter Test Kit J43318 . . . . . . . . . . . . . . . . . . . . . . 375

. . . . . . . . . . . . . . . . . . . . . .372

. . . . . . . . . . 372

Brake

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TRTS0930

Warnings and Cautions

General Information | 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.

Before starting a vehicle:

• Ensure adequate fuel level

• Sit in the driver's

Place

•

shift lever in neutral

parking brake

Set the

seat

Before working on a vehicle or leaving the cab with engine running:

• Ensure ignition is off while hands are within the clutch housing area.

•

shift lever in neutral

Place

Set the

parking brake

When parking the vehicle or leaving the cab:

• Place shift lever in neutral

•Set the parking brake

Cauti

on: 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:

1. Place shift lever in neutral

Lift the drive wheels off of the ground or discon-

2. nect the driveline

operate the vehicle if Alternator light is lit or if

Do not gauges indicate low voltage.

Block the wh

•

eels

2016.01.15

Transmission Models | General Information

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

Transmission Models

TRTS0930

2016.01.15

TRTS0930

Diagnostic Procedures

General Information | Diagnostic Procedures

Purpose: Observe the transmission gear display.

1. Key on.

2. Observe gear display.

Note: An “88” may show up in the dash at key

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

• If “-” (1 dash) on gear display, go to Step D.

• If “--” (2 dashes) or “**” (2 stars) on gear dis- play, 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)

on.

Purpose: Confirm that the engine will crank and

start.

1. Attempt to start engine

• No engine crank, lever is in neutral an

displa

y is “N” (neutral). See

Relay

Contact Test” on page 268.

• No engine crank, lever is in neutral an

displa

y is blank. See “Power

est” on page 22.. If no problems found,

OEM for gear display problem.

• No engine crank and lever is

erify shift lever or push button is in neutral.

- V

- 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 bl

OEM for gear display problem.

• Engine cranks and gear display is “N” (neutral), go to Step

“Start Enable

-Up Sequence

d gear

refer

NOT in neutral.

ank. Refer

• Fault Code F on gear display, go to Step D.

• Neutral “N” on gear display, go to Step B.

2016.01.15

Diagnostic Procedures | General Information

TRTS0930

Purpose: Confirm the transmission will engage a

gear from neutral.

1. Attempt to engage a gear.

• If gear engaged and drives, go to Step E.

• If the gear display indicates a solid “gear num-

ber” but no drive or reverse, perf B

ox Control Test” on page 282

• If unable to engage a g

an Au

toShift, perform “AutoShift Will

age a Gear from Neutral Test” on page 288

Eng

• If unable to engage a g

UltraShift DM3, perform “UltraShift DM

Not Engage a Gear from Neutral T

Will page 29

• If unable to engage a g

an UltraShift AW3, perform “UltraShift AW3 Clutch Engagement Test” on page 302

ear and transmission is

orm “Front

Not

est” on

Purpose: Check for active or Inactive fault codes.

1. Check for active fault codes.

Note: If no problem found, refer to OEM for

oblem.

• If codes are present, See “Fault Code Isol

Procedure

• 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)

See “Front Box Control Test” on page 282.

• If no codes and gear display is“--” (2

or “**” (2 T

est” on page 22.

Index” on page 8.

stars), See “Power-Up

display

ation

dashes)

Sequence

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

record codes an ca

Codes,

357).

• If active transmission component or Fault

Codes, See “Fault

dex” on page 8.

Code Isolation Procedure

ll 1-800-826-HELP

Fault

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TRTS0930

Fault Code Retrieval/Clearing

General Information | 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.

1. Place the shift lever in neutral.

2. Set the parking brake.

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 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.

Note: An “88” may show up in the dash at key on,

which is a normal power-up test of the display.

and

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

SERVICE

Short

Code 13

pause

(1/2 sec)

3 Flashes

SERVICE

Long Pause

(3-4 sec)

off

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).

off

• Two digit fault codes will be displayed in the gear display. Some vehicle may be equipped with a service light.

Code 21

2 Flashes

SERVICE

1 Flash

SERVICE

Short

pause

(1/2 sec)

2016.01.15

Fault Code Retrieval/Clearing | General Information

RTS0930

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 Ser-

viceRanger, to clear fault codes.

1. Place shift lever in neutral.

2. Set parking brake.

with engine off.

off

system to power

3. Turn key on

Turn key off and on 6 times within 5 seconds ending with key on.

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 down

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.

Note: This procedure requires ServiceRanger 3.0 or later

and an approved RP1210A communications adapter that supports J1939 communications.

Detecting Components

1. Connect the service PC to the 39 diagnostic port connector with

J19 RP1210A communications adapter.

2. Start the ServiceRanger program and verify

connection has J1939 data link.

•

If the TECU is not detected by ServiceRanger, proceed to the Electrical Pretest procedure ensure the TECU ponents are properly connected J19

Viewing Fault Codes

View the Vehicle Fault Codes screen in ServiceRanger and verify if any Active or Inactive codes have been set.

been established

39 data link.

vehicle's 9-way

an approved

that a

with the vehicle's

has power, and that all com-

the vehicle's

1. If an Active code is

information and

this manual for the Active code. Do not clear

in code

s at this time.

2. If only Inactive codes are present, record the vehi-

cle fault information and clear all fault codes. test the vehicle

present, record the vehicle fault

proceed to Diagnostic Proced

to verify proper operation.

ure

any

Road

2016.01.15

TRTS0930

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.

General Information | Fault Code Retrieval/Clearing

2. View the Ve Clear All.

Refresh the screen to ver been cleared, and that no Active

hicle Fault Codes screen and select

ify all Inactive codes have

codes are present.

2016.01.15

Fault Code Isolation Procedure Index | General Information

Fault Code Isolation Procedure Index

Fault Codes SPN PID SID FMI Description

11 629 254 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)

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 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

29 969 372 4, 5 Remote throttle enable

31 1485 218 2, 3, 4, 5, 14 Momentary Engine Ignition Interrupt Relay

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 60 2, 3, 4, 10 Rail Position Sensor

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)

(MEIIR)

TRTS0930

2016.01.15

TRTS0930

General Information | Fault Code Isolation Procedure Index

Fault Codes SPN PID SID FMI Description

52 59 59 2, 3, 4, 7 Gear Position Sensor

56 161 161 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

Symptom-Driven Diagnostics Index | General Information

TRTS093

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

2016.01.15

TRTS0930

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.

PD Mode is only to be used by a trained service technician in an authorized dealer.

General Information | Product Diagnostic (PD) Mode

If the fault is detected during PD Mode the gear dis-

• play will display the active fault. The warning to will only sound will stop when the fault is Inactive. The faul stay in the gear display until the system is powered down.

: Active codes set during PD Mode will not be

Note

stored as Inactive.

7. If a fault is detected, exit PD Mode and perf corresponding Fault Isolation Procedure.

To exit PD Mode, turn the key off.

when the fault is active and the tone

t will

orm the

This procedure is to be used prior to performing fault isolation procedures for component-type codes when there are no Active codes present.

To enter PD Mode:

Note: Vehicle will not start in PD Mode. You must turn vehi-

cle key off to exit PD Mode.

1. Vehicle must be stationary, engine off, ng brake.

parki

2. Turn the key off and on 2 times, starting with

ending with

on and

Note: Dash may

mal power-up test of the display.

3. The gear display will flash a 25 then a solid

(Pro

duct Diagnostic Mode) and the

activated.

The service light shall flash code 25 once indicatin no cod

es. The service light shall solid to Act

indicate PD Mode

ive code is detected or PD Mode is exited.

key on.

display an 88 at key on. This is a nor-

until such time that an

set vehicle

key

mode will be

then illuminate

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.

5. Refer to PD Mode section in Fault Isolation proce-

6. PD will remain in gear display until an active faul

2016.01.15

dure for the Inactive fault to be diagnosed.

has been set during the procedure.

PD Mode fault is

olation

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.

TRTS0930

Possible Causes

The pretest can be used for:

• Low batteries

• Starter/Battery connections

• Main power harness to the Transmission Co

ntrol Unit (TECU)

Additional Tools

• Basic hand tools

• Eaton Test Adapter Kit

• Digital Volt/Ohm meter

• Troubleshooting Guide

• Battery Load tester

• ServiceRanger a PC-based service tool

Electronic

2016.01.15

TRTS0930

Component Identification

TECU Power Harness

OEM is responsible for overcurrent protection on this circuit.

Electrical Pretest Procedures | Electrical Pretest

2016.01.15

1. 30 AMP

TECU Connector (Vehicle Interface)

Fuse

Electrical Pretest | Electrical Pretest Procedures

RETRATSTTAB ERYP LUS 2

RETRATSETTABRY M INUS 2

RETRATSETTABRY M INUS 1

RETRATS TTAB ERY P LUS 1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

RATS OT SREPMUJ LAUD - KNAB REP SEIRETTAB OWT - SKNAB YRETTAB OWT TER

REWOP 3 NEG .SRIAP YB LELLARAP NI DETCENNOC ERA SEIRETTAB SUPPLI

ED BY

A SULP HTOB( RETRATS OT TSESOLC YRETTAB ND MINUS)

RETRATS ETTABRYM INUS 1

RETRATSTTABERYP LUS 1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

AMG

LERAY

ENNOCSID HTIW KNAB REP SEIRETTAB OWT - SKNAB YRETTAB OWT CT

EV DNA BAC ROF TCENNOCSID - SRIAP YB LELLARAP NI DETCENNOC ERA SEIRETTAB HIC

LE START -

PAC TNEMNIATRETNE DNA TROFMOC BAC "EGRAHCSID PEED" SEDIVORP RIAP DETCENNOCSID ABIL

ITY.

C DNA RETRATS OT TSESOLC TES YRETTAB MORF DEILPPUS REWOP 3 NEG OMMONTO CAB POWER

ETTAB UCE 3 NEGRY MINUS

TAB UCE 3 NEGTERYPLUS

ETTAB UCE 3 NEGRYMINUS

RETRATSETTAB RY M INUS 1

RETRATSTTABERYP LUS 1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

IRETTAB RUOF - KNAB YRETTAB ENOES

REWOP 3 NEG .LELLARAP NI DETCENNOC ERA SEIRETTAB SUPPLIED FROM

HTOB( .REWOP BAC HTIW RETRATS OT TSESOLC YRETTABP

LUS AND MINUS)

TAB UCE 3 NEGTERYPLUS

ETTAB UCE 3 NEGRYMINUS

TTAB BACERYPLUS

TAB UCE 3 NEGTERYPLUS

TTAB BAC ERY PLUS

Preferred +12 Volt Connections

TRTS0930

2016.01.15

TRTS0930

Preferred +12 Volt Connections

Electrical Pretest Procedures | Electrical Pretest

NUS

AB UCE 3 NEG RY MI

B UCE 3 NEG TERYPLUS

ETT

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

GEN 3 ECU BATTERY PLUS

12 VOLT

BATTERY

NOITUBIRTSID REWOP MODULE

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

CAB BATTERY PLUS

Starter Battery Plus

12 VOLT

BATTERY

12 VOLT

BATTERY

TIWS TCENNOCSID EVITAGEN YRETTAB - SKNAB YRETTAB OWTCH

DEVICES)

12 VOLT

BATTERY

OLTAGEDROP

WOL ROF DEZIMITPO HTGNEL DNA EZIS SELBAC .RETRATSV

YRETTAB M INUS

OVER CURRENT

(POWER BUS AND

MODULE

AB RETRATSTTERY PLUS

DISTRIBUTION

POWER

AB RETRATSTTERYPLUS

TAB RETRATS TERY MINUS

TTAB NO DETCENNOC SUNIM DNA SULP REWOP ,LELLARAP NI DETCENNOC ERA SEIRETTAB ERY CLO OT TSES EHT

EWOP 3 NEG .EDISNI DEROTS ELCIHEV NEHW NWOD REWOP TA DETCENNOCSID ERA SEIRETTAB RSUPPL

D OT NOITCENNOC ELBAC ELCIHEV FO TNIOP TA NOITCENNOC EVITAGEN .RETRATS EHT OT TSESOLC IS

TAB RETRATS TERYMINUS

TTAB ELCIHEVERY MINUS

IED FROMBATTERY

CONNECT SW ITCH

TAB UCE 3 NEGTERYPLUS

ETTAB UCE 3 NEGRYMINUS

STARTER

2016.01.15

GEN 3 ECU BATTERY MINUS

STARTER BATTERY CONNECTION

GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.

12 VOLT

BATTERY

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)

12 VOLT

BATTERY

STARTER BATTERY MINUS

CAB BATTERY PLUS

GEN 3 ECU BATTERY PLUS

STARTER BATTERY PLUS 1

GEN 3 ECU BATTERY MINUS

STARTER BATTERY MINUS 1

Electrical Pretest | Electrical Pretest Procedures

STARTER BATTERY PLUS

STARTER BATTERY MINUS

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

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)

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

MAG

RELAY

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

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

STARTER BATTERY MINUS

STARTER BATTERY PLUS

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

+ -

BATTERY

12 VOLT

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)

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

CAB BATTERY

PLUS

STARTER BATTERY PLUS

STARTER BATTERY MINUS

STARTER BATTERY PLUS

GEN 3 ECU BATTERY

MINUS

CAB BATTERY

PLUS

GEN 3 ECU BATTERY

PLUS

Preferred +24 Volt Connections

TRTS0930

2016.01.15

TRTS0930

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

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

BATTERY

MINUS

STARTER BATTERY

PLUS

STARTER BATTERY

MINUS

VEHICLE BATTERY

MINUS

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

STARTER BATTERY

MINUS

STARTER BATTERY

PLUS

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

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

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

POWER

DISTRIBUTION

MODULE

(POWER BUS AND

OVER CURRENT

DEVICES)

STARTER BATTERY

MINUS

STARTER BATTERY

PLUS

STARTER

CAB BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

GEN 3 ECU BATTERY

PLUS

STARTER BATTERY CONNECTION

GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.

Preferred +24 Volt Connections

Electrical Pretest Procedures | Electrical Pretest

2016.01.15

Electrical Pretest | Electrical Pretest Procedures

TECU Ignition Circuit

TRTS0930

13 14

1. TECU connector (vehicle interface)

2. 10 AMP only, manual resetting circuit

P fuse

10 AM

3. Ignition Key Switch

29 30

15 16

7389

1 2

24 25

breaker OR

32 33

27 28

18 19

10611 12

4 5

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.

2016.01.15

TRTS0930

+ Battery

10 11

C D B F G A

J1939 Low

J1939 High

J1939 Data Link

Electrical Pretest Procedures | Electrical Pretest

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 diagnostic connector the read

ing. The reading should be 60 ohms of

resistance (between 50 and 70.)

3. Check resistance between Pin C and Pin A and resistance readi

between Pin D and Pin A.

ngs should be 10K ohms or greater (open cir-

cuit).

Note: Pin C

= J1939+, Pin D = J1939-, Pin A is a chas-

sis ground

• If an Inactive data link fa by the TE on pag

CU, See “Product Diagnostic (PD) Mode

e 11. PDM should be utilized before any fur-

ther steps are taken.

Pin C and Pin D and

ult code is being reported

9-way

record

These two

the

”

2016.01.15

Electrical Pretest | Electrical Pretest Procedures

–

Batteries

30 AMP fuse

Transmission ECU

4-Pin Diagnostic Port

(Located at the left rear

corner of the transmission.)

4-Pin Diagnostics Port

4-way

B - Service Bat. + C - Service Bat. A - Service Ignition +

VOLTS

COM

Battery Negative Post

Warning! - Do Not Load Test at Diagnostic Port

Electrical Pretest

TRTS0930

Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground

supplies at the batteries.

1. Key off.

2. Remove and clean all battery and batter

conn

ections.

y-to-frame

3. Remove and clean ground supply to engine ECU.

4. Inspect starter/battery and inline 30 amp

er connections for corrosion or damaged con-

hold

fuse

tacts.

5. Measure voltage across

batteries.

• If voltage is 11 to 13 volts on a 12- volt system

22 to 26 on a 24 volt system, refer

to OEM guidelines for battery load test. Repair or repla

ce batteries as required. Go to Step

Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diag-

nostic connector.

1. Locate diagnostic port on Transmission Harness.

2. Key on.

3. Measure voltage between Pin C and the batter

tive post.

nega

• If voltage is 0.70 volts or less, go to Step

• If voltage is outside of range, repair or replace

batteries and charging system

as required.

Repeat this step.

• If voltage is outside of range, repair battery

ground supply to Transmission Electrical Control Unit (TECU). Repeat test.

2016.01.15

TRTS0930

4-Pin Diagnostics Port

4-way

B - Service Bat. + C - Service Bat. A - Service Ignition +

4-Pin Diagnostic Port

(Located at the left rear

corner of the transmission.)

Warning! - Do Not Load Test at Diagnostic Port

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.

2. Key on.

3. Measure voltage between Pin B and Pin C.

• If voltage is within 0.6 volts of battery

Step

go to

voltage,

Purpose: Measure proper ignition voltage at the

transmission harness 4-way diagnostic connector.

1. Key on.

Warning: Do not load test at the diagnostic port.

2. Measure voltage between Pin A and Pin C.

Warning! - Do Not Load Test at Diagnostic Port

4-Pin Diagnostics Port

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

test complete.

voltage,

• If voltage is outside of range, Repair battery

power supply to TECU. Fuse may be bl

own.

Repeat test.

• If

voltage is outside of range, repair ignition power supply to TECU. Fuse may be blown. Repeat test.

2016.01.15

Power-Up Sequence Test | Electrical Pretest Procedures

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:

• Vehicle Harness

• Shift Control Device

• TECU

TRTS0930

2016.01.15

TRTS0930

VOLUME CONTROL

SERVICE

SHIFT

Eaton Fuller Transmissions

Component Identification

Electrical Pretest Procedures | Power-Up Sequence Test

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

Power-Up Sequence Test | Electrical Pretest Procedures

Power-Up Sequence Test

TRTS0930

Purpose: Measure battery voltage. Visually inspect the batteries, inline fuse and power and ground

supplies at the batteries.

1. Key off.

2. Remove and clean all battery and batter

conn

ections.

3. Remove and clean ground supply to engine ECU.

4. Inspect starter/battery and

er connections for corrosion or damaged con-

hold tacts.

5. Measure voltage across

voltage is 11 to 13 volts on a 12-volt

• If

or 22 to battery load test. Repair or replace batteries as req

• If voltage is outside of range, repair or replace

batteries and charging system Repeat this step.

26 on a 24-vo

uired. Go to Step

inline 30-amp fuse

batteries.

lt system, proceed with

y-to- frame

system

as required.

Purpose: Measure proper battery voltage at the

transmission harness 4-way diagnostic connector.

1. Locate diagnostic port on Transmission Harness.

2. Key on.

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

to Step

• If voltage is outside of range, repair battery

power supply to TECU. Fuse may be blown. Repeat test.

Purpose: Measure proper ignition voltage at the

transmission harness 4-way diagnostic connector.

voltage,

Purpose: Verify proper ground path between the batteries and the transmission harness 4-way diag-

nostic connector.

1. Locate diagnostic port on Transmission Harness.

2. Key on.

3. Measure voltage between Pin C and the batter

ive post.

negat

• If voltage is 0.70 volts or less, go to Step

• If voltage is outside of range, repair battery

ground

supply to TECU. Repeat test.

1. Key on.

2. Measure voltage between Pin A and Pin C.

• If voltage is within 0.6 volts of battery

to Step

• If voltage is outside of range, repair Ignition

power supply to ECU. Fuse may be bl Repeat test.

voltage,

own.

2016.01.15

TRTS0930

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?

• If vehicle is not equipped with a Shift Lever, to Step

• If vehicle is equipped with a Shift Lever, go to St

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

Devic

• If an Eaton Push Button Shift Control, go to

Step

• If an OEM J1939 Shift Device, refer to OEM for

troubleshooting procedures.

Purpose: Visually observe the Service light during

key-on power up.

1. Key on.

2. Observe Service light.

Note: If Service light is flashing, go to

Procedure.

• If Ser

• If Service light never lights, go to Step

• If Service light is on steady, replace Shift Con-

Purpose: Measure the voltage supply at the Shift

Control device.

1. Key off.

2. Disconnect Shift Control 30-way connector.

vice light illuminates for 1 second

turns off, test complete.

trol. Go to Step V.

Diagnostics

and

3. Key on.

4. Measure voltage between Pin C1 and

Control 30-way.

Shift

• If voltage is within 1 volt of battery replace S

• If voltage is outside of range, go to Step I.

hift Control

. Go to Step V.

Pin J3 on the

voltage

2016.01.15

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