Eaton Transmission F-5405B-DM3 Service Manual

Troubleshooting Guide

Eaton Gen III Automated Transmissions TRTS0930 EN-US

August 2013

UltraShift® AutoShift® UltraShift® PLUS Linehaul Active Shifting (LAS) UltraShift® PLUS Linehaul Small Step Efficiency (LSE) UltraShift® PLUS Multipurpose Extreme Performance (MXP) UltraShift® PLUS Multipurpose High Performance (MHP) UltraShift® PLUS Vocational Active Shifting (VAS) UltraShift® PLUS Vocational Construction Series (VCS) UltraShift® PLUS Vocational High Performance (VHP) UltraShift® PLUS Vocational Multipurpose Series (VMS) UltraShift® PLUS Vocational Extreme Performance (VXP) UltraShift® PLUS Passenger Vehicle (PV)

Model:

F-5405B-DM3 F-6405B-DM3 F-14E316B-LSE F-15E316B-LSE F-17E316B-LSE FM-15E316B-LSE 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 FO-10E310C-VAS FO-12E310C-VAS FO-14E310C-VAS FO-16E310C-VAS FOM-14E310C-VAS F-5505B-DM3 F-6505B-DM3 RTLO-18918A-AS3 RTLO-20918A-AS3 RTLO-22918A-AS3 RTLOM-16913L-DM3 RTO-10910B-AS3 RTOM-16910B-DM3 FO-14E310C-LAS FO-16E310C-LAS

FO-18E310C-LAS FOM-14E310C-LAS FOM-15E310C-LAS FOM-16E310C-LAS FM-14E310B-LAS FM-15E310B-LAS EO-11E406B-PV FOM-15E310C-VAS FOM-16E310C-VAS FO-10E308LL-VCS FO-11E308LL-VCS FO-12E308LL-VCS FO-14E308LL-VCS FO-16E308LL-VCS FO-17E308LL-VCS FO-16E313A-VHP FO-18E313A-VHP FO-20E313A-VHP FO -10E309A LL-VMS FO -11E309ALL-VMS FO -12E309ALL-V MS

FO -14E30 9ALL-VMS FO -16E309ALL-VM S FO -17E309ALL-V MS FO-14E313B-MHP FO-16E313B-MHP FO-18E313B-MHP FO-20E313B-MHP FO-14E318B-MXP FO-16E318B-MXP FO-18E318B-MXP FO-20E318B-MXP FO-22E318B-MXP FO-14E318B-VXP FO-16E318B-VXP FO-18E318B-VXP FO-20E318B-VXP FO-22E318B-VXP EO-11E406B-PVER EO-11E406B-PVHR EO-11E406B-PV

TRTS0930

Table of Contents

able of Contents

General Information

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . .1

Suggested Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Transmission Models Included . . . . . . . . . . . . . . . . . . .3

Diagnostic Procedures. . . . . . . . . . . . . . . . . . . . . . . . . .6

Fault Code Retrieval/Clearing

Retrieving Fault Codes Manually . . . . . . . . . . . . . 10

Clearing Fault Codes Manually . . . . . . . . . . . . . . . 11

Retrieving Fault Codes with ServiceRanger . . . . . 11

Clearing Fault Codes with ServiceRanger. . . . . . . 12

Fault Code Isolation Procedure Index . . . . . . . . . . . . .13

Symptom-Driven Diagnostics Index . . . . . . . . . . . . . .15

Product Diagnostic (PD) Mode . . . . . . . . . . . . . . . . . .16

Electrical Pretest Procedures

Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

TECU Power Harness. . . . . . . . . . . . . . . . . . . . . . 19

Heavy-Duty Electric Clutch Actuator (ECA)

Power Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Preferred +12 Volt Connections . . . . . . . . . . . . . . 22

Preferred +24 Volt Connections . . . . . . . . . . . . . . 24

TECU Ignition Circuit . . . . . . . . . . . . . . . . . . . . . . 26

J1939 Data Link. . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Power-Up Sequence Test. . . . . . . . . . . . . . . . . . . . . . .32

Fault Isolation Procedures

Fault Code 11 - No TECU Operation. . . . . . . . . . . . . . .40

Fault Code 12 - Improper ECU Configuration. . . . . . . .44

Fault Code 13 - J1939 Shift Control Device . . . . . . . . .48

Fault Code 14 - Invalid Shift Lever Voltage

(without Park Pawl) . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Fault Code 14 - Invalid Shift Lever Voltage

(with Park Pawl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Fault Code 15 - HIL Shift Device Configuration . . . . . . 64

Fault Code 16 - High Integrity Link (HIL) . . . . . . . . . . .68

Fault Code 17 - Start Enable Relay

Fault Code 18 - ECA Communication Fault. . . . . . . . . .84

Fault Code 19 - CAN ECA Message Fault . . . . . . . . . . .88

Fault Code 21 - Auto Neutral Park Brake Switch . . . . . 92

Fault Code 22 - ABS CAN Message Fault . . . . . . . . . . . 98

Fault Code 26 - Clutch Slip . . . . . . . . . . . . . . . . . . . .102

Fault Code 27 - Clutch Disengagement . . . . . . . . . . .106

(SER) Circuit . . . . .80

Fault Code 28 - Clutch System. . . . . . . . . . . . . . . . . .112

Fault Code 29 - Remote Throttle Enable. . . . . . . . . . .118

Fault Code 31 - Momentary Engine Ignition

Interrupt Relay (MEIIR) Test . . . . . . . . . . . . . . . . . . .122

Fault Code 32 - Loss of Switch Ignition Power Test .128

Fault Code 33 - Low Battery Voltage Supply . . . . . . . 132

Fault Code 34 - Weak Battery Voltage Supply

Fault Code 35 - J1939 Communication Link . . . . . . . 144

Fault Code 36 - J1939 Engine Message. . . . . . . . . . . 150

Fault Code 37 - Power Supply . . . . . . . . . . . . . . . . . .156

Fault Code 41 - Range Failed to Engage. . . . . . . . . . . 162

Fault Code 42 - Splitter Failed to Engage . . . . . . . . . .168

Fault Code 43 - Range Solenoid Valve . . . . . . . . . . . . 174

Fault Code 44 - Inertia Brake Solenoid Coil . . . . . . . . 180

Fault Code 45 - High Capacity (HCIB)

or Low Capacity (LCIB) Inertia Brake Failure . . . . . . .186

Fault Code 46 - Splitter Direct and

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190

Fault Code 51 - Rail Position Sensor . . . . . . . . . . . . .196

Fault Code 52 - Gear Position Sensor . . . . . . . . . . . .202

Fault Code 56 - Input Shaft Speed Sensor . . . . . . . . . 208

Fault Code 57 - Main Shaft Speed Sensor . . . . . . . . .214

Fault Code 58 - Output Shaft Speed Sensor. . . . . . . . 218

Fault Code 61 - Rail Select Motor . . . . . . . . . . . . . . .224

Fault Code 63 - Gear Select Motor. . . . . . . . . . . . . . .230

Fault Code 64 - ECA Fault . . . . . . . . . . . . . . . . . . . . .236

Fault Code 65 - ECA Speed Sensor Fault . . . . . . . . . . 240

Fault Code 66 - ECA Battery Voltage Fault . . . . . . . . .248

Fault Code 67 - ECA Ignition Voltage Fault. . . . . . . . . 254

Fault Code 68 - Grade Sensor . . . . . . . . . . . . . . . . . . 260

Fault Code 71 - Unable to Disengage Gear. . . . . . . . .264

Fault Code 72 - Failed to Select Rail. . . . . . . . . . . . . .270

Fault Code 73 - Failed to Engage Gear . . . . . . . . . . . .276

Fault Code 74 - Engine Speed Response Fault. . . . . .282

Fault Code 75 - Power Down In Gear. . . . . . . . . . . . . 286

Fault Code 81 - Gear Engagement Detected. . . . . . . . 290

Fault Code 83 - Shift Lever Missing. . . . . . . . . . . . . .294

Fault Code 84 - Shift Control Fault Code 85 - Shift Control Device Incompatible. . . 302

Fault Code 99 - Direction Mismatch. . . . . . . . . . . . . .306

Indirect

Device Not Configured . 298

. . . . . . 138

2013.08.7

Table of Contents TRTS0930

Symptom Isolation Procedures

Up/Down Button Test. . . . . . . . . . . . . . . . . . . . . . . . .310

Start Enable Relay Contact Test . . . . . . . . . . . . . . . . .314

J1587 Data Link Test . . . . . . . . . . . . . . . . . . . . . . . . .320

Front Box Control Test . . . . . . . . . . . . . . . . . . . . . . . .326

AutoShift Will Not Engage a Gear

from Neutral Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .332

Heavy-Duty UltraShift PLUS Will Not Eng

a Gear from Neutral Test . . . . . . . . . . . . . . . . . . . . . .340

UltraShift DM3 Will Not Engage a Gear

from Neutral Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .348

UltraShift AW3 Clutch Engagement Test

AutoShift AS3 Shift Complaint Test . . . . . . . . . . . . . .358

Heavy-Duty UltraShift PLUS Shift Co

UltraShift DM3 Shift Complaint Test . . . . . . . . . . . . .378

UltraShift AW3 Shift Complaint Test . . . . . . . . . . . . .388

Shift Lever Back Light Test . . . . . . . . . . . . . . . . . . . .396

age

. . . . . . . . . .354

mplaint Test . . .368

Appendix

Connector Pin Descriptions

Non-ECA Products Transmission Controller

38-Way (Vehicle Interface Connector) . . . . . . . . 402

Push Button Shift Control 30-Way Connector . . 403

Cobra Lever 8-Way Connector . . . . . . . . . . . . . . 403

Non-ECA Products Transmission Controller

38-Way (Eaton Supplied Assembly). . . . . . . . . . 404

Heavy-Duty & Medium-Duty UltraShift PLUS Transmission Controller

38-Way (Vehicle Interface Connector) . . . . . . . . 405

Heavy-Duty UltraShift PLUS T Controller 38-Way (Eaton Supplied Assembly

Medium-Duty UltraShift PLUS T Controller 38-Way (Eaton Supplied Assembly

Wiring Diagrams

UltraShift DM3 6-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 408

UltraShift DM3 6-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 410

UltraShift AW3 6-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 412

UltraShift AW3 6-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 414

Medium-Duty UltraShift PLUS Mo

Diagram with Analog Shifter . . . . . . . . . . . . . . . 416

Medium-Duty UltraShift PLUS Mo

Diagram with Push Button Shifter . . . . . . . . . . . 418

AutoShift 10-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 420

ransmission

) . 406

ransmission

) . 407

dels Wiring

AutoShift 10-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 422

UltraShift 10-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 424

UltraShift 10-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 426

UltraShift 13-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 428

UltraShift 13-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 430

AutoShift 18-Speed Wiring Diagram

with Analog Shifter. . . . . . . . . . . . . . . . . . . . . . . 432

AutoShift 18-Speed Wiring Diagram

with Push Button Shifter . . . . . . . . . . . . . . . . . . 434

Heavy-Duty UltraShift PLUS Mo

Wiring Diagram with Analog Shifter. . . . . . . . . . 436

Heavy-Duty UltraShift PLUS Mo

Wiring Diagram with Push Button Shifter . . . . . 438

Eaton Cobra Lever Wiring Diagram . . . . . . . . . . 440

OEM Shift Lever Wiring Diagram . . . . . . . . . . . . 441

Eaton Push Button Wiring Diagram . . . . . . . . . . 442

OEM J1939 Shift Input Device Wiring Diagram . 444 Heavy Duty UltraShift PLUS Mo

ECA Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . 445

Proper Clutch Operation

Check For Proper Clutch Operation Confirm Proper Clutch Adjustment

and Clutch Brake Contact . . . . . . . . . . . . . . . . . . 447

Clutch Grease Interval Service Procedure . . . . . 448

ServiceRanger Procedure . . . . . . . . . . . . . . . . . . . . .449

dels

. . . . . . . . . . 446

2013.08.7

TRTS0930 General Information | Warnings and Cautions

Warnings and Cautions

Warning: Follow the specified procedures in the indicated

order to avoid personal injury

Note: Additional relevant information not covered in the

service procedure.

Before starting a vehicle:

• Ensure adequate fuel level

• Sit in the driver's seat

• Place shift lever in neutral

• Set the parking brake

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

When parking the vehicle or leaving the cab:

• Place shift lever in neutral

• Set the parking brake

Caution: Follow the specified procedures in the indicated

order to avoid equipment malfunction or damage.

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:

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.

2013.08.6

For parts or service call us

Pro Gear & Transmission, Inc.

1 (877) 776-4600

(407) 872-1901

parts@eprogear.com

906 W. Gore St.

Orlando, FL 32805

Suggested Tools | General Information TRTS0930

Suggested Tools

Air Gauges

• 2 (0-100) PSI Air Gauges

Volt/Ohm Meter

• Roadranger Pin Out Adapter Jumper Kit

• RR1009HY

PC-based Service Tool

• ServiceRanger 3

• Contact Eaton: 1 (800) 826-4357

Shift Lever Tester

• Eaton Service Parts: 1 (800) 826-4357

• P/N 691795

Publication Title

Eaton Test Adapter Kit

• SPX / Kent-Moore 1 (800) 328-6657

• P/N J-43318

6-Pin Deutsch Diagnostic Adapter

• SPX / Kent-Moore 1 (800) 328-6657

• P/N J-38500-60A

9-Pin Deutsch Diagnostic Adapter

• SPX / Kent-Moore 1 (800) 328-6657

• P/N J-44012

Service Publications

TRSM0930 Fuller UltraShift Transmission Service Manual

TRTS0930 Fuller UltraShift Transmission Troubleshooting Guide

TRDR0930 Fuller AutoShift Transmission Driver Instructions

TRDR0940 Fuller UltraShift Transmission Driver Instructions

TRDR1110 Fuller UltraShift PLUS Transmission Driver Instructions

For more information call 1-800-826-HELP (826-4357)

2013.08.6

TRTS0930 General Information | Transmission Models Included

RTO-1X910-AS3

RTO(M)-1X910-DM3

RTLO-1X918-AS3

RTLO(M)-1X913-DM3

F(0)-X406X-AW3

F(0)-X405X-DM3

F(0)-X406X-DM3or

Transmission Models Included

2013.08.7

Transmission Models Included | General Information TRTS0930

F(M)-1XE316-LSE

FO-1XE309LL-VMS, FO-1XE308LL-VCS

FO-1XE318-VXP/MXP, FO-1XE313-MHP/VHP

F(O)(M)-1XE310-LAS/VAS

EO-11E406B-PV(ER)(HR)

2013.08.7

TRTS0930 General Information | Transmission Models Included

2013.08.7

Diagnostic Procedures | General Information TRTS0930

Diagnostic Procedures

Overview

None

Detection

None

Fallback

None

Possible Causes

None

2013.08.16

TRTS0930 General Information | Diagnostic Procedures

Component Identification

None

2013.08.16

Diagnostic Procedures | General Information TRTS0930

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 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

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

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

• “#” (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)

Purpose: Confirm that the engine will crank and

start.

1. Attempt to start engine

• No engine crank, lever is in neutral and gear

display is “N” (neutral). See “Start Enable Relay Contact Test” on page 314.

• No engine crank, lever is in neutral and gear

display is blank. See “Power-Up Sequence Test” on page 32.. 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

• Fault Code F on gear display, go to Step

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

2013.08.16

TRTS0930 General Information | Diagnostic Procedures

Purpose: Confirm the transmission will engage a

gear from neutral.

1. Engage a gear.

Note: AutoShift will not engage a gear from neutral

test. UltraShift will not engage a gear from neutral test. UltraShift PLUS Product will not engage a gear from neutral test, or UltraShift AW3 Clutch Engagement test depending on transmission type.

• Unable to engage gear (ie. flashing gear dis-

play with down arrows, or solid “N”).

• Solid “#” (gear number) but no drive. See

“Front Box Control Test” on page 326. Gear engaged and drives, go to Step

Purpose: Check for active or Inactive fault codes.

1. Check for active fault codes.

Note: If no problem found, refer to OEM for display

problem.

• If codes are present, See “Fault Code Isolation

Procedure Index” on page 13.

• 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 326.

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

or “**” (2 stars), See “Power-Up Sequence Test” on page 32.

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 13.

2013.08.16

Fault Code Retrieval/Clearing | General Information TRTS0930

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 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 16. for details.

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

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

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)

2013.08.6

TRTS0930 General Information | Fault Code Retrieval/Clearing

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.

3. Turn key on with engine off.

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

off

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.

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 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.

• 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.

2013.08.6

Fault Code Retrieval/Clearing | General Information 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.

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.

2013.08.6

TRTS0930 General Information | Fault Code Isolation Procedure Index

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

18 520200 34 9 ECA communication

19 520273 248 9 CAN ECA message

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

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)

2013.08.16

Fault Code Isolation Procedure Index | General Information TRTS0930

Fault Codes SPN PID SID FMI Description

46 771 38 3, 4, 5 Splitter Indirect Solenoid Valve

51 60 60 2, 3, 4, 10 Rail Position Sensor

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

64 788 34 2, 7, 12 ECA fault

65 5052 192 5, 2 ECA Speed Sensor fault

66 520271 34 3, 4 ECA Battery Voltage fault

67 520274 158 3, 4, 5 ECA Ignition Voltage fault

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

2013.08.16

TRTS0930 General Information | Symptom-Driven Diagnostics Index

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

UltraShift PLUS will not engage a gear from Neutral UltraShift PLUS Will Not Engage a Gear from Neutral

Test

UltraShift PLUS shift complaint UltraShift PLUS Shift Complaint Test

2013.08.6

Product Diagnostic (PD) Mode | General Information 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.

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, set vehicle parking brake.

• 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.

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 works with the following Inactive codes:

11, 13, 14, 15,16, 17, 18, 19, 21, 22, 29, 33, 34, 35, 36, 43, 44, 46, 51, 52, 56, 57, 58, 61, 63, 65, 66, 67, 74, and 99.

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 nor-

mal 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.

2013.08.16

TRTS0930 General Information | Product Diagnostic (PD) Mode

2013.08.16

Electrical Pretest | Electrical Pretest Procedures TRTS0930

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) and to the optional Electric Clutch Actuator (ECA).

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

• Basic hand tools

• Eaton Test Adapter Kit

• Digital Volt/Ohm meter

• Troubleshooting Guide

• Battery Load tester

• ServiceRanger a PC-based service tool

2013.08.23

TRTS0930 Electrical Pretest Procedures | Electrical Pretest

Component Identification

TECU Power Harness

OEM is responsible for overcurrent protection on this circuit.

2013.08.23

1. 30 AMP Fuse

2. TECU Connector (Vehicle Interface)

Electrical Pretest | Electrical Pretest Procedures TRTS0930

Heavy-Duty Electric Clutch Actuator (ECA) Power Harness

OEM is responsible for overcurrent protection on this circuit. ECA products are 12-volt only.

1. 50 AMP Fuse

2013.08.23

TRTS0930 Electrical Pretest Procedures | Electrical Pretest

Heavy-Duty Electric Clutch Actuator (ECA) Power Harness

Important: The TECU and ECA must be wired to a

non-switched power source at the battery. If a disconnect switch is required, the recommended practice is to wait a minimum of three minutes before using the disconnect switch.

It is the OEM responsibility to provide power and ground to the TECU and ECA from the battery which supplies the starter.

The power (+) connection must include overload protection per Federal Motor Carrier Safety Regulations, Section

393.31. The TECU main power and ground must be a direct connection from the battery posts to the TECU connector.

At 120° C, these conductors must be able to carry 30 amps @ 9 volts with no more than 0.05 ohms per wire (0.1 ohms total) for a total voltage drop from the battery posts to the TECU connector not to exceed 3.0 volts. ECA main power and ground must be able to carry 50 amps @ 9 volts with no more than 0.025 ohms per wire (.05 ohms total) at 120° C. Duration of the 50 amp current draw will not exceed 20 milliseconds.

The main power 30-amp fuse connection for the TECU must be identified with a tag at the battery.

The main power 50-amp fuse connection for the ECA must be identified with a tag at the battery.

The battery positive post and negative post must be disconnected PRIOR to any type of welding on any Fuller Automated Transmission-equipped vehicles.

Removal of fuses is not recommended as the method of disconnecting power from the ECU. Making and breaking a circuit through tin plated terminals (e.g. ring terminals, fuses, most connectors) will destroy the plating on the terminal. Opening a switch contact or the main power link is the recommended method of interrupting power.

Application of more than 36 volts to the system (such as jump-starting) will cause system shutdown and possible electrical component damage.

Do not switch off the battery and ignition power and ground to the TECU during the engine start process.

2013.08.23

Electrical Pretest | Electrical Pretest Procedures TRTS0930

ETRATST

ERYP LUS2

RETRAT

SETTABRYM INUS2

RETRATSETTABRYM IN

US 1

RET

RAT

TTA

BERY

P LUS

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

RATS OT SREPMUJ LAUD - KNAB REP SEIRETTAB OWT - SKNA

B YRETTAB OWT

TER

REWOP 3 NEG

.SRIAP YB LELLARAP NI

DETCENNOC ERA SEIRETTAB

SUPPLIED BY

A SU

LP HTOB( RE

TRATS OT TSE

SOL

C YRETTAB

NDMINUS)

RETRATS

TABRY

M I

NUS 1

RETRATSTTABERYP LUS1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

AMG

LERAY

ENNOCSID HTIW KNAB REP SEIRETTAB OWT - SKNAB YRETTAB OWT CT

V DNA BA

C ROF

NNOCSID - SR

B LE

LLARA

P NI DETCENNOC ERA SEIRETTA

B H

ICL

START

PAC TNEMN

IATRET

NE DNA TRO

FMOC BAC

"EGRAHCSID PEE

D" S

EDIVORP RIA

DETCEN

NOCS

D ABILITY.

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

OMMONTO

CAB POWER

ETTAB UCE 3 NEGR

YMI

NUS

UCE 3 NEGTERYPL

ETTAB UCE 3 NEGRY

INU

RETRATSETTABRYM 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 HTI

W RE

TRATS OT TSESOLC YRETTABPLU

AND MINUS)

TAB UCE 3 NEGTERYPLUS

ETTAB UCE 3 NEGRYM

NUS

TTAB BACERYPLUS

TAB UCE 3 NEGTE

YPLUS

TTAB BAC ERY PLUS

Preferred +12 Volt Connections

2013.08.23

TRTS0930 Electrical Pretest Procedures | Electrical Pretest

Preferred +12 Volt Connections

B UCE 3 NEGRY M

B UC

E 3 NEGTERY PLUS

12 VOLT

BATTERY

12 VOLT

BATTERY

EIRET

TAB ERY CLOOT TS

GEN 3 ECU BATTERY PLUS

12 VOLT

BATTERY

RETRATS EHT OT TSESOLC ISCONNECT SW ITCH

12 VOLT

BATTERY

NOITUBIRTSID REWOP M ODULE

12 VOLT

BATTERY

12 VOLT

BATTERY

P TA DETCENNOCSID ERA SEIRETTAB RSUPPLIED

12 VOLT

BATTERY

CAB BATTERY PLUS

Starter Battery Plus

12 VOLT

BATTERY

YRETTABM INU

AB RETRATSTTERYPL

TIWS TCENNOCSID EVITAGEN YRETTAB - SKNAB YRETTAB OWTCH

(POWER BUS AND

OVER CURRENT

DISTRIBUTION

DEVICES)

MODULE

POWER

12 VOLT

BATTERY

WOL ROF DEZIMITPO HTGNEL DNA EZIS SELBAC .RETRATSVOLTAGEDROP

AB RETRATSTTERYPLU

TAB RETRATSTERY MINUS

TTAB NO DETCENNOC SUNIM DNA SULP REWOP ,LELLARAP NI DETCENNOC ERA S

12 VOLT

BATTERY

STARTER

EWOP 3 NEG .EDISNI DEROTS ELCIHEV NEHW NWOD REWO

T NOITCENNOC ELBAC ELCIHEV FO TNIOP TA NOITCENNOC EVITAGEN .

D O

TAB RETR

YMINU

ATSTER

TAB ELCIHE

RY MINUS

MBATTER

FRO

TAB UCE 3 NEGTERYPLUS

ETTAB UCE 3 NEGRYMINUS

EHT

2013.08.23

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 TRTS0930

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

2013.08.23

TRTS0930 Electrical Pretest Procedures | Electrical Pretest

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

2013.08.23

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