Eaton Transmission FO-6406A-ASW Service Manual

Troubleshooting Manual

Gen II Automated Transmissions TRTS0062 EN-US

May 2013

FO-6406A-ASW FO-6406A-ASX FO-8406A-ASW FO-8406A-ASX RT-14910B-A S2 RTLO-14918A-AS2 RTLO -16918A-AS2 RTLO-18918A-AS2 RTLO-20918A-AS2 RTLO -22918A-AS2 RTO-1 071 0B-AS2 RTO-1 091 0B-AS2 RTO-1 091 0B-DM2

RTO-12710B-AS2 RTO-12910B-AS2 RTO-12910B-DM2 RTO-14710B-AS2 RTO-14710C-A S2 RTO-14910B-AS2 RTO-14910B-DM2 RTO-14910C-A S2 RTO -16710C-AS2 RTO -16910B-AS2 RTO -16910B-DM2 RTO -16910C-AS2 RTO-18910B-AS2

TRTS0062

Table of Contents

General Information

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

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

Air Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Volt/Ohm Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PC-based Service Tool “ServiceRanger” . . . . . . . . .2

Shift Lever Tester . . . . . . . . . . . . . . . . . . . . . . . . . .2

Eaton Test Adapter Kit . . . . . . . . . . . . . . . . . . . . . . .2

6-Pin Deutsch Diagnostic Adapter . . . . . . . . . . . . . .2

. . . . . . . . . . . . . .3

Transmission Models Included . . . .

Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .4

Fault Code Retrieval/Clearing . . . . . . . . . . . . . . . . . . . .5

Retrieving Fault Codes . . . . . . . . . . . . . . . . . . . . . .5

Clearing Fault Codes . . . . . . . . . . . . . . . . . . . . . . . .6

Driving Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fault Code Isolation Procedure Index . . . . . . . . . . . . .12

Symptom-Driven Diagnostics Index . . . . . . . . . . . . . .14

.

Electrical Pretest Procedure

Electrical System Pretest . . . . . . . . . . . . . . . . . . . . . .15

Power-Up Sequence Pretest . . . . . . . . . . . . . . . . . . . .18

Air Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Fault Isolation Procedure

Fault Code 11: Shift Controller . . . . . . . . . . . . . . . . . .28

Fault Code 12: Transmission Controller . . . . . . . . . . .32

Fault Code 14: Invalid Lever Position . . . . . . . . . . . . .36

Fault Code 16: Eaton Proprietary Link (EPL) . . . . . . . .42

Fault Code 17: Start Enable Relay Coil . . . . . . . . . . . .48

Fault Code 26: Clutch Slip . . . . . . . . . . . . . . . . . . . . . .54

Fault Code 27: Clutch Disengagement . . . . . . . . . . . . .58

.

Fault Code 28: Clutch System Fault Fault Code 31: Momentary Engine Ignition

Interrupt Relay (MEIIR) . . . . . . . . . . . . . . . . . . . . . . . .68

Fault Code 32: Switched System Voltage . . . . . . . . . .74

Fault Code 33: Battery Voltage Supply . . . . . . . . . . . .78

Fault Code 35: J1939 Data Link . . . . . . . . . . . . . . . . .82

Fault Code 41: Range Failed to Engage . . . . . . . . . . . .88

Fault Code 42: Splitter Failed to Engage . . . . . . . . . . .92

Fault Code 43: Range Valve . . . . . . . . . . . . . . . . . . . . .96

Fault Code 44: Inertia Brake Solenoid Coil . . . . . . . .102

Fault Code 46: Splitter Valve . . . . . . . . . . . . . . . . . . .108

Fault Code 51: Rail Select Sensor . . . . . . . . . . . . . . .114

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

Fault Code 52: Gear Select Sensor . . . . . . . . . . . . . .120

Fault Code 56: Input Shaft Speed Sensor . . . . . . . . .124

Fault Code 57: Main Shaft Speed Sensor . . . . . . . . .130

Fault Code 58: Output Shaft Speed Sensor . . . . . . . .134

Fault Code 61: Rail Select Motor . . . . . . . . . . . . . . . .140

Fault Code 63: Gear Select Motor . . . . . . . . . . . . . . .146

Fault Code 65: Logic Power . . . . . . . . . . . . . . . . . . .152

Fault Code 71: Stuck Engaged . . . . . . . . . . . . . . . . . .158

Fault Code 72: Failed to Select Rail . . . . . . . . . . . . . .162

Fault Code 73: Failed to Engage Gear . . . . . . . . . . . .166

Fault Code 74: Failed to Synchronize . . . . . . . . . . . .170

Voltage

. . . . . . . .174

. . . . . .186

Fault Code 81: Gear Engagement D

Fault Code 83: Missing Lever . . . . . . . . . . . . . . . . . .178

Fault Code 91: Power Connection . . . . . . . . . . . . . . .182

Fault Code 92: Weak System Battery Fault Code 93: Loss of J1939 Communication

from the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .190

etected

Symptom Isolation Procedure

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

Front Box Control . . . . . . . . . . . . . . . . . . . . . . . . . . .204

Gear Display Power Supply . . . . . . . . . . . . . . . . . . . .208

Start Enable Relay Contact . . . . . . . . . . . . . . . . . . . .214

AutoShift Will Not Engage a Gear . . . . . . . . . . . . . . .220

UltraShift DM Will Not Engage a Gear . . . . . . . . . . . .228

UltraShift ASW Will Not Engage a Gear . . . . . . . . . . .236

J1587 Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

Range System Test . . . . . . . . . . . . . . . . . . . . . . . . . .248

Splitter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Up/Down Button Test . . . . . . . . . . . . . . . . . . . . . . . .256

UltraShift DM Shift Complaint . . . . . . . . . . . . . . . . . .260

UltraShift ASW Shift Complaint . . . . . . . . . . . . . . . . .266

UltraShift ASW Clutch Engagement . . . . . . . . . . . . .274

Transmission Air Leak . . . . . . . . . . . . . . . . . . . . . . .278

Shift Lever Back Light . . . . . . . . . . . . . . . . . . . . . . . .284

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i

T

able of Contents TRTS0062

Appendix

Connector Pin Descriptions . . . . . . . . . . . . . . . . . . .288

Transmission Controller 18-Way

(Vehicle Interface Connector) . . . . . . . . . . . . . . .288

Transmission Controller 30-W

Shift Controller 30-Way Connector . . . . . . . . . . .291

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . .294

6-Speed and 7-Speed AutoShift . . . . . . . . . . . . .294

6-Speed UltraShift ASW . . . . . . . . . . . . . . . . . . .296

10-Speed AutoShift . . . . . . . . . . . . . . . . . . . . . . .298

10-Speed UltraShift DM . . . . . . . . . . . . . . . . . . .300

18-Speed AutoShift . . . . . . . . . . . . . . . . . . . . . . .302

Eaton Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . .304

OEM Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . .304

Proper Clutch Operation . . . . . . . . . . . . . . . . . . . . . .306

Check For Proper Clutch Operation

Confirm Proper Clutch Adjustment

and Clutch Brake Contact . . . . . . . . . . . . . . . . . .306

Adapter Test Kit J43318 . . . . . . . . . . . . . . . . . . . . . .308

Gray Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . .308

Purple Adapters . . . . . . . . . . . . . . . . . . . . . . . . . .308

Adapter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

Troubleshooting Worksheet . . . . . . . . . . . . . . . . . . .309

ay Connector . . . .289

. . . . . . . . . . .306

ii

2013.07.17

TRTS0062 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.

Before starting a vehicle:

• 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:

• 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: 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 drivelink

Do not operate vehicle if Alternator light is lit or if gauges indicate low voltage.

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1

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 TRTS0062

Suggested Tools

Air Gauges

• 2 (0-100) PSI Air Gauges

Volt/Ohm Meter

• SPX / Kent-Moore 1 (800) 328-6657

• P/N 5505027

PC-based Service Tool “ServiceRanger”

• Contact your OEM

Shift Lever Tester

• Eaton Service Parts 1 (800) 826-4357

• P/N 691795

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

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

2

2013.07.17

TRTS0062 General Information | Transmission Models Included

Transmission Models Included

6-Speed

7-Speed 18-Speed

6-Speed ASW

10-Speed

2013.07.17

10-Speed DM

3

Diagnostic Procedure | General Information TRTS0062

Diagnostic Procedure

Follow the flow chart below for all AutoShift failures. Perform tests and procedures as directed by the flowchart.

Key on.

Retrieve active codes. Note: Scan tool or P.C. may be required if service light is not avialable.

•Perform Electrical System Pretest

Active codes?

YES

NO

• Refer to the Fault Code Isolation Procedure Index to select a Fault Code Isolation Procedure

Observe Gear Display

Can a solid "N" be observed in Gear Display ?

YES

Retrieve Inactive Codes.

Inactive Codes?

NO

Symptom?

NO

YES

Will engine crank ?

•Perform Gear Display Test

• Record and clear codes

• Perform Driving Technique to reproduce the inactive fault code

•Perform Electrical System Pretest

•Perform Air Pretest

• Refer to the Fault Code Isolation Procedure Index to select

a fault code isolation procedure

•Perform Electrical System Pretest

•Perform Air Pretest

•Perform Power-Up Sequence Test

• Refer to Symptom-Driven Diagnostics Table to select a symptom isolation procedure

YES

•Perform Power-Up Sequence Test

•Perform Front Box Control Test

NO

Test complete.

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2013.07.17

TRTS0062 General Information | Fault Code Retrieval/Clearing

2 times

off

on

4 times

off

on

SERVICE

1 Flash

Short

pause

(1/2 sec)

Short

pause

(1/2 sec)

Long Pause

(3-4 sec)

3 Flashes

2 Flashes

Code 13

Code 21

SERVICE

1 Flash

SERVICE

Fault Code Retrieval/Clearing

Retrieving Fault Codes

Retrieve fault codes by enabling self-diagnostic mode.

Note: Use a PC-based Service Tool, such as the ServiceRanger to retrieve fault codes.

1. Place the Shift Lever in neutral.

2. Set the parking brake.

3. Turn the key on but do not start the engine. If the engine is running, you may still retrieve codes; however, do not engage the Starter if the engine stalls.

4. To Retrieve Active Codes: Turn the key off and on 2 times within 5 seconds ending with the key on. After 5 seconds, the Service light begins flashing 2-digit fault codes. If no faults are Active, the Service light will flash Code 25 (no codes).

6. Observe the sequence of flashes on the Indicator 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.

5. To Retrieve Inactive Codes: Start with the key on. Turn key off and on 4 times within 5 seconds ending with the key on. After 5 seconds, the Service light begins flashing 2-digit fault codes. If no faults are Active, the Service light will flash Code 25 (no codes).

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5

Fault Code Retrieval/Clearing | General Information TRTS0062

Clearing Fault Codes

The following procedure clears all Inactive fault codes from the Transmission Controller memory. Active fault codes will be automatically cleared when the fault has been corrected.

Note: You may use a PC-based Service Tool, such as ServiceRanger, to clear fault codes.

1. Place the Shift Lever in neutral.

2. Set the parking brake.

3. Turn the key on, but do not start the engine.

4. Start with the key on. Turn the key off and on 6

times within 5 seconds ending with the key on.

6 times

off

on

Note: If the codes have been successfully cleared, the Service light will come on and stay on for 5 seconds.

5. Turn key off and allow the system to power down.

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2013.07.17

TRTS0062 General Information | Driving Techniques

Driving Techniques

Fault Codes

11 254 12 Shift Controller Component

12 233 12

14 18 2, 4, 5

16 248 2

PID SID FMI Description Type of Code Driving Technique

Transmission Controller

Invalid lever Position Test

Eaton Proprietary Link (EPL)

Component

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat and vibration.

17 237 3, 4

25 NO CODES

26 55 10 Clutch Slip Component

2013.07.17

Start Enable Relay Coil

Component

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat and vibration.

Operate the vehicle under load in highest gear possible with engine speed above 1500 RPM. At a steady speed, quickly and fully press the throttle. The failure is detected when clutch slip occurs.

7

Driving Techniques | General Information TRTS0062

Fault Codes

PID SID FMI Description Type of Code Driving Technique

27 55 7

28 52 3,4,5,7

31 218 3,4

Clutch Disengagement

Clutch System Fault

Momentary Ignition Interrupt Relay

Component

Operate the vehicle. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration and aggressive stops.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include low clutch fluid level, heat and vibration.

Key on. If the fault is present, the system should automatically detect the problem and set the code. This fault is only detected during system power-up. If the fault is not present at power up, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

32 62 4

33 168 4

Switched Voltage Supply

Battery Voltage Supply

Component

35 231 2 J1939 Data Link System

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration, and varying levels of throttle demand. It may take up to 75 seconds to set this fault.

8

2013.07.17

TRTS0062 General Information | Driving Techniques

Fault Codes

41 56 7

42 61 7

PID SID FMI Description Type of Code Driving Technique

Range Failed to Engage

Splitter failed to Engage

System

43 35, 36 3, 4, 5 Range Valve Component

44 53 3, 4, 5

Inertia Brake Solenoid Coil

Component

Operate vehicle and perform several range up shifts and down shifts. The failure is detected after 5 consecutive attempts to complete the same type of range shift. Several shifts (10 or more) may be necessary before the controller confirms the failure.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

46 37, 38 3, 4, 5 Splitter Valve Component

51 60

2, 3, 4, 10

52 59 2, 3, 4

Rail Select Sensor

Gear Select Sensor

Component

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

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9

Driving Techniques | General Information TRTS0062

Fault Codes

56 161 2, 5

57 160 2

58 191 2

PID SID FMI Description Type of Code Driving Technique

Input Shaft Speed Sensor

Main Shaft Speed Sensor

Output Shaft Speed Sensor

Component

61 39 5, 6 Rail Select Motor Component

Select a forward gear and drive at a steady speed no slower than 10 MPH. It may be necessary to operate the vehicle for a prolonged period of time if the cause of the failure is related to heat and vibration.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

63 40 5, 6

Gear Select Motor

Component

65 251 4 Logic Power Component

71 60 7 Stuck Engaged System

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

Engage low gear and allow the vehicle to slowly move forward. While the vehicle is in motion, move the Shift Lever to reverse low and slowly bring the vehicle to a stop. The vehicle will shift into reverse low. Several shifts (10 or more) may be required before operator confirms the failure.

10

2013.07.17

TRTS0062 General Information | Driving Techniques

Fault Codes

PID SID FMI Description Type of Code Driving Technique

72 59 7

73 58 7

74 54 7

83 18 14

Failed to Select Rail

Failed to Engage Gear

Failed to Synchronize

Shift Lever Missing

System

Component

Complete several shifts while the vehicle is in motion, including selections from neutral. Also allow the transmission to complete several automatic shifts.

Operate vehicle and perform several range up shifts and down shifts in the top gears. If this does not set the code, then perform the following. With vehicle stopped, select a drive gear and fully press clutch pedal. Return transmission to neutral. Repeat several times.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

91 236 5

92 168 14

93 231 14

Power Connection

Weak battery Voltage

Loss of engine J1939 communication

System

Key off. If the fault is present, the system will automatically detect the problem during system calibration and set the code Inactive. Possible triggers include corrosion on main battery power and ground.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include, weak vehicle charging system or battery integrity.

Key on. If the fault is present, the system should automatically detect the problem and set the code. If the fault is not present at key on, operate the vehicle and attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration.

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11

Fault Code Isolation Procedure Index | General Information TRTS0062

Fault Code Isolation Procedure Index

Fault Codes

11 254 12 Shift Controller Component

12 233 12 Transmission Controller Component

14 18 2, 4, 5 Invalid lever Position Component

16 248 2 Eaton Proprietary Link (EPL) Component

17 237 3, 4 Start Enable Relay Coil Component

25 No Codes

26 55 10 Clutch Slip Component

27 55 7 Clutch Disengagement Component

28 52 3,4,5,7 Clutch System Fault Component

31 218 3,4 Momentary Engine Ignition Interrupt Relay Component

32 62 4 Switched System Voltage Component

33 168 4 Battery Voltage supply Component

P I D S I D F M I

Description Type of Code Page Number

35 231 2 J1939 Data Link System

41 56 7 Range Failed to Engage System

42 61 7 Splitter Failed to Engage System

43 35, 36 3, 4, 5 Range Valve Component

44 53 3, 4, 5 Inertia Brake Solenoid Coil Component

46 37, 38 3, 4, 5 Splitter Valve Component

51 60

52 59 2, 3, 4 Gear Select Sensor Component

56 161 2, 5 Input Shaft Speed Sensor Component

57 160 2 Main Shaft Speed Sensor Component

58 191 2 Output Shaft Speed Sensor Component

61 39 5, 6 Rail Select Motor Component

63 40 5, 6 Gear Select Motor Component

2, 3, 4, 10

Rail Select Sensor Component

12

2013.07.17

TRTS0062 General Information | Fault Code Isolation Procedure Index

Fault Codes

P I D S I D F M I

Description Type of Code Page Number

65 251 4 Logic Power Component

71 60 7 Stuck Engage System

72 59 7 Failed to Select Rail System

73 58 7 Failed to Engage Gear System

74 54 7,10,12 Failed to Synchronize System

83 18 14 Shift Lever Missing System

91 236 5 Power Connection System

92 168 14 Weak System Battery Voltage System

93 231 14

Loss of J1939 Communication from the Engine

System

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13

Symptom-Driven Diagnostics Index | General Information TRTS0062

Symptom-Driven Diagnostics Index

Symptom Isolation Procedure Page Number

Electrical System Test Electrical System Test

Gear display shows a dash Front Box Control Test

Gear display not working Gear Display Power Supply Test

Engine starting system complaint Start Enable Relay Test

AutoShift will not engage a gear AutoShift Will Not Engage A Gear Test

UltraShift DM will not engage a gear UltraShift DM Will Not Engage A Gear Test

UltraShift ASW will not engage a gear UltraShift ASW Will Not Engage A Gear Test

No J1587 communications J1587 Data Link Test

Unsatisfactory range shift Range System Test

Unsatisfactory splitter shift Splitter System Test

Unable to shift transmission with up/down buttons Up-Down Button Test

UltraShift DM shift complaint UltraShift DM Shift Complaint Test

UltraShift ASW shift complaint UltraShift ASW Shift Complaint Test

UltraShift ASW clutch engagement complaint UltraShift ASW Clutch Engagement Test

Transmission air leak Transmission Air Leak Test

No lights on Shift Lever Shift Lever Back Light Test

14

2013.07.17

TRTS0062 Electrical Pretest Procedure | Electrical System Pretest

Electrical System Pretest

Overview

The test does not relate to any specific fault code, but must be completed before performing “Fault Code Isolation Table” procedures. The Electrical Pretest verifies the batteries are fully charged.

Detection

There is no detection process specifically for the basic electrical supply; however, failures of this type are generally detected by the transmission or operator as some other fault code or symptom.

Fallback

There is no fallback for the Electrical Pretest; however, it may effect other systems.

Possible Causes

This pretest can be used for any of the following:

• Low batt

Starter-battery connections

•

eries

Additional Tools

• Basic hand tools

• Eaton Test Adapter kit

• Digital volt/ohm meter

• Battery load tester

2013.07.17

15

Electrical System Pretest | Electrical Pretest Procedure TRTS0062

VOLTS

V

COM

A

+

–

+

–

Component Identification

16

2013.07.17

TRTS0062 Electrical Pretest Procedure | Electrical System Pretest

VOLTS

V

COM

A

+

–

+

–

Electrical System Pretest

Purpose: Measure battery voltage, visually inspect

A

batteries.

1. Key off.

2. Inspect starter, battery and in-line fuse holder con-

nections for integrity.

3. Measure voltage across batteries.

• If voltage is 11–13 volts on a 12-volt system or 22–26 on a 24-volt system, go to Step

B.

• If voltage is outside of range, repair or replace

batteries and charging system as required. Then measure voltage again.

Purpose: Verify the batteries pass a load test.

B

1. Key off.

2. Load test the Batteries.

• If the batteries maintain the specified load, test

complete.

• If the batteries fail the Load Test, replace the damaged battery(s). Go to Step

A.

2013.07.17

17

Power-Up Sequence Pretest | Electrical Pretest Procedure TRTS0062

Power-Up Sequence Pretest

Overview

A failure during the self-check indicates a failure of the Shift Controller.

Detection

The power-up self-check is performed automatically each time the key is turned on. Turn the key on and watch the Service light. If power up stops with the Service light constantly on, or it never comes on, self-check has failed.

Fallback

If self-check fails, the product cannot perform any operations.

Possible Causes

This test can be used for the following:

• Shift Controller

• Vehicle Harness

Additional Tools

• Basic hand tools

• Eaton Test Adapter kit

• Digital volt/ohm meter

18

2013.07.17

TRTS0062 Electrical Pretest Procedure | Power-Up Sequence Pretest

Component Identification

Side view

of pushbutton

shift control

Transmission controller

30-way connector

VOLUME

Top view

of pushbutton

shift control

CONTROL

SERVICE

R

N

D

SHIFT

Eaton Fuller Transmissions

H

L

Pushbutton Shift Control

Eaton Shift Lever

2013.07.17

19

Power-Up Sequence Pretest | Electrical Pretest Procedure TRTS0062

VOLTS

V

COM

A

K

J

H

G

F

E

D

C

B

A

321

Power-Up Sequence Pretest

Purpose: Visually identify if the vehicle is equipped

A

with a Shift Lever.

1. Is vehicle equipped with a Shift Lever?

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

B.

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

D.

Purpose: Verify proper power up of the transmis-

B

sion shift controller.

1. Key on.

2. Observe Service light.

Note: If Service light is flashing, see “Diagnostic

Procedure” on page 4.

Purpose: Confirm switched ignition voltage to the

C

transmission shift controller.

1. Key off.

2. Disconnect Shift Controller 30-way connector.

3. Key on.

4. Measure voltage across batteries and record find-

ing.

5. Measure voltage between Shift Controller 30-way

Pin C1 and Pin K3.

• If Service light lights for one second and turns off, Test complete.

• If Service light never comes on, go to Step

C.

• If Service light is on steady, replace Shift Con- trol. Repeat this step.

• If voltage is within 1 volt of battery voltage,

replace Shift Control

. Go to Step B.

• If voltage is outside of range, no ignition

power. Repair ignition power supply to transmission, go to Step

B.

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2013.07.17

TRTS0062 Electrical Pretest Procedure | Power-Up Sequence Pretest

Purpose: Visually identify if the Shift Lever is an Ea-

D

ton Shift Lever or an OEM Shift Lever.

1. Is vehicle equipped with an Eaton-supplied Shift

Lever or an OEM-supplied Shift Lever?

• If Eaton Shift Lever, go to Step

E.

• If OEM Shift Lever, go to Step I.

Purpose: Visually observe the Service light during

E

key-on power up.

1. Key on.

2. Observe Service light.

Note: If Service light is flashing, see “Diagnostic

Procedure” on page 4.

Purpose: Test operation of the transmission Ser-

F

vice light.

1. Key off.

2. Locate Shift Controller.

3. Disconnect Shift Controller 30-way connector.

4. Place a jumper across Shift Controller 30-way con-

nector Pin J1 and Pin H2.

321

K

J

H

G

F

• If Service light illuminates for one second and

turns off, test complete.

• If Service light never comes on, go to Step

• If Service light is on steady, go to Step

F.

H.

E

D

C

B

A

321

• If Service light turns on, replace Shift Control Go to Step

E.

• If Service light never comes on, go to Step G.

.

2013.07.17

21

Power-Up Sequence Pretest | Electrical Pretest Procedure TRTS0062

OHMS

V

COM

A

K

J

H

G

F

E

D

C

B

A

321

1

2

3

4

5

6

7

8

Purpose: Confirm OEM Service light power wire

G

continuity and test for a short to ground.

1. Key off.

2. Disconnect Shift Lever 8-way connector.

3. Measure resistance between:

- Shift Controller 30-way Pin H2 and Shift Lever

8-way connector Pin 6

- Shift Controller 30-way connector Pin H2 and

ground.

Purpose: Test the transmission Service light.

H

1. Key on.

2. Locate Shift Controller.

3. Disconnect Shift Controller 30-way connector.

• If Service light turns off, replace Shift Control Go to Step

• If Service light remains on, repair OEM har- ness as required. Go to Step

Purpose: Measure battery voltage to the Service

I

light

1. Key off.

E.

.

2. Locate Service light connector on Vehicle Harness.

3. Measure voltage across Pin A and Pin B on Service

light connector.

• If resistance between Pin H2 and Pin 6 is

0–0.3 ohms and If resistance between Pin H2 and ground is 10K ohms or open circuit [OL], replace Shift Lever. Go to Step

E.

• If any of the above conditions are not met,

repair Vehicle Harness between Shift Controller and Shift Lever, go to Step

E.

4. Key on.

• If voltage is within 2 volts of total battery volt-

age for 1 second, then 0 volts, test complete.

• If no voltage is measured, go to Step

• If voltage is within 2 volts of battery voltage continuously, go to Step

K.

J.

22

2013.07.17

TRTS0062 Electrical Pretest Procedure | Power-Up Sequence Pretest

K

J

H

G

F

E

D

C

B

A

321

Purpose: Test voltage to the transmission Service

J

light

1. Key off.

2. Locate Shift Controller.

3. Disconnect Shift Controller 30-way connector.

4. Place a jumper across Shift Controller 30-way con-

nector Pin J1 and Pin H2.

5. Key on.

6. Measure voltage across Service light connector.

Purpose: Measure voltage drop across the OEM

K

transmission Service light

1. Key on.

2. Locate Shift Controller.

3. Disconnect Shift Controller 30-way connector.

4. Measure voltage across Service Light connector

Pin A and Pin B.

VOLTS

A

B

A

V

COM

• If no voltage is measured, replace Shift Control. Go to Step I.

• If voltage is within 2 volts of battery voltage, repair Vehicle Harness as required. Go to Step I.

2013.07.17

• If voltage is within 2 volts of battery voltage. Replace Shift Control

. Go to Step I.

• If no voltage is measured, repair Vehicle Harness as required. Go to Step

I.

23

Air Pretest | Electrical Pretest Procedure TRTS0062

Air 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 that the basic air input is OK before testing individual system functions.

Detection

There is no detection process specifically for the basic air supply; however, failures of this type are generally detected by the transmission or operator as some other type of fault code or symptom.

Fallback

There is no fallback mode for air pretest; however, it may affect other systems.

Possible Causes

This pretest can be used for any of the following:

• Low air pressure

• Contaminated air

• Air Filter-Regulator

Additional Tools

• Basic hand tools

• 0-100 PSI Air pressure gauge

24

2013.07.17

TRTS0062 Electrical Pretest Procedure | Air Pretest

Air filter/regulator

Component Identification

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25