Eaton Transmission RTLO-16618A Service Manual
Troubleshooting Guide
Fuller Transmissions
TRTS0070
October 2007
RTLO-11610B
RTLO-11610B-T2
RTLO-12610B
RTLO-12610B-T2
RTLO-12713A
RTLO-12913A
RTLO-13610B
RTLO-13610B-T2
RTLO-14610A
RTLO-14610B
RTLO-14610B-T2
RTLO-14613B
RTLO-14618A
RTLO-14713A
RTLO-14718B
RTLO-14913A
RTLO-14918B
RTLO-14918B-T2
RTLO-15610B
RTLO-15610B-T2
RTLO-16610B
RTLO-16610B-T2
RTLO-16618A
RTLO-16713A
RTLO-16713A-T2
RTLO-16718B
RTLO-16913A
RTLO-16913A-T2
RTLO-16918B
RTLO-16918B-T2
RTLO-17610B
RTLO-17610B-T2
RTLO-18610B
RTLO-18610B-T2
RTLO-18718B
RTLO-18718B-T2
RTLO-18913A
RTLO-18913A-T2
RTLO-18918B
RTLO-18918B-T2
RTLO-20913A
RTLO-20918B
RTLO-20918B-T2
RTLO-22918B
RTLOC-16909A-T2
RTLOF-11610B
RTLOF-11610B-T2
RTLOF-12610B
RTLOF-12610B-T2
RTLOF-12713A
RTLOF-12913A
RTLOF-13610B
RTLOF-13610B-T2
RTLOF-14610B
RTLOF-14610B-T2
RTLOF-14613B
RTLOF-14618A
RTLOF-14713A
RTLOF-14718B
RTLOF-14913A
RTLOF-14918B
RTLOF-14918B-T2
RTLOF-15610B
RTLOF-15610B-T2
RTLOF-16610B
RTLOF-16610B-T2
RTLOF-16618A
RTLOF-16713A
RTLOF-16713A-T2
RTLOF-16718B
RTLOF-16913A
RTLOF-16913A-T2
RTLOF-16918B
RTLOF-16918B-T2
RTLOF-17610B
RTLOF-17610B-T2
RTLOF-18610B
RTLOF-18718B
RTLOF-18913A
RTLOF-18913A-T2
RTLOF-18918B
RTLOF-18918B-T2
RTLOF-20913A
RTLOF-20918B
RTLOF-20918B-T2
RTLOF-22918B
RTLOFC-16909A-T2
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
General Warnings
General Warnings
Before starting a vehicle:
1. Sit in driver’s seat
2. Place shift lever in neutral
3. Set the parking brake
working on a vehicle or leaving the cab with engine
Before
running:
1. Place shift lever in neutral
2. Set parking brake
3. Block wheels
not release the parking brake or attempt to select a gear
Do
the air pressure is at the correct level.
until
parking the vehicle or leaving the cab:
When
1. Place shift lever in neutral
2. Set the parking brake
not operate if alternator lamp is lit or if gauges indicate low
Do
.
voltage
ry (+) and (-) must be disconnected prior to any type of
Batte
g on the vehicle.
weldin
Suggested Tools:
• Volt/Ohm Meter
SPX
/ Kent-Moore 1 (800) 328-6657
P/N
5505027
• PC-based Service Tool “Service Ranger”
Con
tact your OEM
• Data Link Tester
Ea
ton Service Parts 1 (800) 826-4357
P/N MF-KIT-04
• Shift Lever Tester
Ea
ton Service Parts 1 (800) 826-4357
691795
P/N
• Eaton Test Adapter Kit
/ Kent-Moore 1 (800) 328-6657
SPX
P/N J-43318
• 6-Pin Deutsch Diagnostic Adapter
/ Kent-Moore 1 (800) 328-6657
SPX
J-38500-60A
P/N
information and assistance, call the Roadranger Help
For
at 1-800-826-HELP (4357) (Mexico: 01-800 826-HELP
Desk
(4357). You may also find more information about Eaton
Transmissions at www.Roadranger.com.
Fuller
ry effort has been made to ensure the accuracy of the
Eve
information
ration
informatio
contained in this manual. However, Eaton Corpo-
makes no warranty, expressed or implied, based on the
n provided.
Table of Contents
Introduction
Introduction ............................................................ 1-1
Diagnostic Procedure ............................................. 1-2
Suggested Test Fixures
Suggested Test Fixures .......................................... 1-3
General Procedures
Top 2 Basic Operation and Overview ...................... 1-5
System Problem ..................................................... 1-8
Driving Techniques
Driving Techniques ............................................... 1-12
Fault Code Isolation Procedure Index
Fault Code Isolation Procedure Index ................... 1-14
Pretest
Pneumatic Pretest .................................................. 2-1
Fault Code Procedures
Fault Code: 62
(SID: 26,40,53-56, FMI: 3,4)
DDEC III - Shift Solenoid or Lockout
Solenoid ......................................................... 2-4
Fault Code: 537, 536
(SID: 40, 51, FMI: 11)
Cummins - Shift Solenoid or Lockout
Solenoid ......................................................... 2-8
Fault Code: 66,67
(SID: 40,51, FMI: 5,6)
Caterpillar - Shift Solenoid or Lockout
Solenoid ....................................................... 2-12
Fault Code: 44,43
(SID: 10,11, FMI: 3,4)
MACK - Shift Solenoid or Lockout
Solenoid ....................................................... 2-16
Fault Code: 62
(SID: 26,40,53-56, FMI: 7)
DDEC III - Mechanical System Not
Responding .................................................. 2-20
Fault Code: 544
(PID: 191, FMI: 7)
Cummins - Mechanical System Not
Responding .................................................. 2-26
Fault Code: 68
(PID: 191, FMI:7)
Caterpillar - Mechanical System Not
Responding .................................................. 2-32
FaultCode: 38
(PID: S32, FMI: 7)
MACK - Mechanical System Not
Responding ...................................................2-38
Symptom Procedures
Symptom Driven Diagnostics Table ........................3-1
Air Leak Test - T2 Convertible Only .........................3-2
Air Leak Test - 10 Speed Onoy.................................3-6
Air Leak Test - 13 and 18 Speed Only....................3-10
Splitter System Test ..............................................3-14
Appendix
Service Information ............................................... A-1
Top 2 System Overview .......................................... A-2
Splitter Cylinder Assembly -
10 Speed Only (old design) ............................ A-9
Splitter Cylinder Assembly -
RTL-XX710 Model (latest design) ................ A-11
Splitter Cylinder Assembly -
RTLO-XX713 and XX718 (old design) .......... A-13
Splitter Cylinder Assembly -
RTLO-XX710 Model (latest design) ............. A-16
Splitter Cylinder Assembly -
RTLO-XX913 and XX918 (latest design) ...... A-18
Table of Contents
Fault Isolation Procedures
Introduction
Purpose and Scope of Manual
This manual is designed to provide detailed information necessary to perform diagnostic and troubleshooting procedures for the
Eaton Fuller transmissions listed on the cover.
How to Use This Manual
The key to using this manual is to follow the Diagnostic Procedure (see page 1-2) first. This procedure takes you step-by-step
through the tests and procedures to help to diagnose the transmission failure.
1-1
General Procedures
Diagnostic Procedure
Follow the flowchart below for all Top 2 transmission failures. Perform tests and procedures in order as directed by the flowchart.
It is recommended to use the MPSI Pro-Link 9000 Diagnostics Tool or an approved engine manufacturers diagnostic tool to
diagnose Fault Codes.
Key on.
Retrieve active engine codes.
Active engine
codes?
NO
Is Top 2 operating
properly?
NO
Retrieve active transmissions codes.
Active transmission
codes?
NO
YES
YES
YES
• Diagnose and repair active engine
codes per OEM recommendations.
• Clear active and inactive codes
with MPSI scan tool.
• Test drive and confirm
vehicle repair.
• Perform Electrical Pretest.
• Refer to the Fault Code Isolation
Procedure Index to select a Fault
Code Isolation Procedure.
Diagnostic Procedure
Retrieve Inactive Codes.
Inactive Codes?
NO
Symptom?
NO
Test complete.
YES
YES
• Record and clear codes.
• Perform Pneumatic Pretest.
• Perform Driving Technique to
reproduce the inactive fault code.
• Refer to Symptom-Driven Diagnostics Table to select a symptom
isolation procedure.
• Perform Pneumatic Pretest.
• Refer to Top 2 Basic Operation
and Overview section.
1-2
Suggested Test Fixures
Note: Only one gauge required.
Range Cylinder
Suggested Test Fixures
2
1
3
1. 0-100 PSI gauge
2. 5/32" air line
3. 5/32" push-to-connect to 1/8" NPTF
1/8" Air Lines
5
4. 1/8" nipple
5. 1/8" tee
2
1
3
4
6
5
7
4
8
9
1. 0-100 PSI gauge
2. 5/32" air line
3. 5/32" push-to-connect to 1/8" NPTF
4. Elbow
1-3
5. 1/8" tee
6. Elbow assembly
7. 1/8" air line
8. Grip nut
9. Compression sleeve
5/32" Air Lines
Suggested Test Fixures
2
1
3
4
1. 0-100 gauge
2. 5/32" air line
3. 5/32" push-to-connect to 1/8" NPTF
4. Elbow
6
5
7
8
9
5. 1/8" Tee
6. Elbow assembly
7. 5/32" air line
8. Grip nut
9. Compression sleeve
Suggested Test Fixures
1-4
General Procedures
Top 2 Basic Operation and Overview
The Top 2 transmission shifts like a normal 10, 13, or 18 speed transmission until the lever is put into the Auto (Top 2) Mode. The
transmission shifts automatically between the top two gears based on engine speed and load.
When the transmission is in the Auto Mode the system will:
a. Shift the transmission between the top two gears.
b. Increase or decrease engine speed during a shift.
c. Momentarily interrupts cruise control or engine brake during the shift, then resumes.
Upshift Procedure
1. Upshift the transmission through the shift pattern 7th H position for the 13/18-speed Convertible models and 8th gear
for 10-speed models. Double-clutching during lever shifts and breaking torque during button shifts.
2. When the engine has reached the shift point use the normal double-clutching procedure and move the shift lever into
AUTO gear.
Note: The position of the shift button does not matter when moving the lever into the AUTO position. It is recommended to leave
the shift button in the forward position so it is ready when you want to make a downshift into 7th H position for 13/18-speed
models or 8th gear for 10-speed models.
3. When the engine has reached the shift point the transmission will automatically shift into high gear.
Downshift Procedure
1. To downshift from high gear into the AUTO position:
Once the engine has reached the shift point the transmission will automatically downshift.
2. To downshift from AUTO position:
a. Make sure the shift button is in the forward position.
b. Once the engine has reached the shift point move the lever to the next lower lever position while double-clutching.
3. Continue downshifting through the shift pattern, double-clutching during lever shifts and breaking torque during button
shifts.
1-5
Driving Tips
General Procedures
Top 2 Basic Operation and
• When the transmission is making a shift in the AUTO Mode, depressing the clutch pedal or moving the lever into the
neutral position may cause the Top 2 to miss the shift.
• To activate Top 2 Mode, the transmission must be shifted to the highest lever position when the engine has reached its
normal shift point of at least 1400 rpm and vehicle speed is at least 40 mph. (Example: On a Super 10 the highest lever
position is 9th and 10th gears).
• Shifting the lever into the Auto position below 1400 rpm does not activate the AUTO Mode. If the operator moves the
shift lever into the Auto lever position below the engine’s normal shift point, the transmission remains in MANUAL MODE.
• Shift points in AUTO Mode vary depending on the following things:
1. Throttle Position
2. Engine Load
3. Engine Brake Status
4. Terrain
• HOLD Mode is available when the Top 2 Cruise option is enabled. The cruise option allows the operator to turn off the
Top 2 function with the master cruise switch. When the AUTO position and Cruise Control is turned OFF, the transmission
holds in the current gear disabling auto and manual split shifts until one of the following happens:
1. The Cruise Control is turned back ON.
2. The lever is moved to the neutral position.
3. The clutch pedal is fully depressed.
• Transmission HUNTING may occur under certain driving conditions. Raising or lowering vehicle cruise speed alleviates
this condition.
Overview
1-6
General Procedures
Definitions
Break Torque Releasing engine power or load from the transmission and drivetrain by releasing the throttle or depressing
the clutch pedal.
Double-Clutch The shifting technique used when moving the shift lever to the next lever position. Procedure: Depress
clutch pedal, move lever to neutral, let up clutch pedal, accelerate or decelerate engine to obtain synchronous, depress clutch pedal again, and move lever into gear.
Preselect Moving the shift button just prior to the starting shift. The shift button should not be moved while the shift
lever is in neutral.
Ratio Step Amount of change between two gear ratios expressed as a percentage. Example: The ratio step from 1st gear
to 2nd gear is 35%.
Shift Button The button on the side of the shift knob used to change gears.
Synchronous The point at which the input gearing speed (engine speed) matches the output gearing speed (road speed)
and a shift can occur without grinding.
Auto Position The highest lever position where the Top 2 shifts between the top two gear positions, also referred to as Top
2 Mode.
Hold Mode The transmission holds the current gear at the request of the driver by turning off the Cruise Control switch
while in the AUTO mode.
Manual Mode Driver operated splitter shifts when in the AUTO position.
Hunting A condition causing the transmission to upshift and downshift repeatedly. This condition is dependent on
road speed, throttle position, and engine load.
1-7
Fault Isolation Procedures
C
ode
FMI
Code 62
Note:
Clearing DDEC Fault Codes
Retrieving DDEC Fault Codes
System Problem
If the system malfunctions, the transmission defaults to manual mode or hold mode indicating one the following faults occurred:
• The Top 2 Valve experienced an open or short in the circuit. The check engine light turns on and the system defaults to
Manual Mode.
• A failed component in the system prevented the splitter system from making the shift. After three (3) attempts made over
a time period of about 9 seconds the system times out. The check engine light does not turn on. Shifting the transmission
to neutral or depressing the clutch obtains manual shifting mode. The Top 2 function is inactive until the vehicle is
stopped and the key is turned off for at least 10 seconds.
Fault Code Retrieval/Clearing
The procedure for retrieving and clearing fault codes differs between engine OEMs. Here are the procedures for Detroit Diesel,
Caterpillar, Cummins, and Mack.
Detroit Diesel
Code Retrieval/ Clearing
System Problem & Fault
Retrieving DDEC Fault Codes
All transmission related faults are identified by Code 62.
Fault isolation is determined by the FMI code that can only
be retrieved with a diagnostic tool. The MPSI Pro-Link 9000
diagnostic tool must be used to accurately diagnose the Top
2 system.
ode
Code 62- Shorted Circuit
Fault
Fault Code 62- Open Circuit
Fault Code 62- Mechanical System Not
Flash codes may be retrieved by manually flashing the codes
Responding
on the check engine light to retrieve the nature of the system
fault but when performing troubleshooting diagnostics a
diagnostic tool must be used to prevent misdiagnosis.
FMI
3
4
7
The following illustrates a code flashing sequence
for code 62:
1. 6 Flashes
2. Short pause (1/2 sec)
3. 2 Flashes
Code 62
After the engine lights have been activated:
Active fault codes are flashing on
the Stop Engine light.
Inactive fault codes are flashing on
the Check Engine light.
Note:
If there are no fault codes, a fault code
25 is flashed.
Clearing DDEC Fault Codes
Use an MPSI Pro-Link 9000 diagnostic tool
to clear fault codes.
1-8
Cummins
Retrieie
ving
Cummins Fa
ult
Codes
Stop
Warning
Tomomovevetoto
the next c
ode:
Tomomovetoto
the prerevi
ous
code::::
NOTE:
Cl
earing
Cummins Faulult Cododeses
C
ode 221
R
ving
Cummins
ult
General Procedures
Codes
There are two methods of retrieving the fault codes:
Using a Cummins-approved diagnostic tool to
retrieve active and inactive fault codes.
Manually flashing the active codes on the Stop
Warning
procedure:
1. Key off.
2. Turn the Diagnostic switch on or connect
the shorting plug to the diagnostic connector.
3. Key on.
The followingillustrates a code flashingsequence fora
code 221:
1. 1 Flash
2. Short pause (2 sec)
3. 2 Flashes
4. Short pause (1or 2sec)
5. 2 Flashes
lights on the cab panel using the following
6. Short pause (1 or 2 sec)
7. 1 Flash
8. Short pause (1 or 2 sec)
9. 1 Flash
and
ode
After the lights have been activated, the lights will
continue to flash the same color.
the
switch to the + position.
the
Adjustswitchto the-position.
NO
come on and stay on.
Go tothe Fault code listing. See fault code list located
inside this troubleshooting guide.
earing
Use a Cummins-approveddiagnostic tool to clear fault
codes.
If there are no active faultcodes bothlightswill
Cummins
ode
MovetheIdleSpeedAdjust
ous
code
MovetheIdleSpeed
1-9
Caterpillar (CAT)
Retrieie
ving CAT F
ault
Codes
Code6262
Check Engine
Clea
ring CAT F
ault
Codes
Check
Engine
Check Engine
Check Engine
Note:
R
ving
ault
Fault Isolation Procedures
Codes
There are two methodsof retrieving the fault codes:
Usinga Caterpillar-approved diagnostic tool
to retrieve the active and inactive fault codes
Manually flashing the codes on the Check
Engine
light using the following procedure:
1. Make sure the Cruise Control switch is
off.
2. Hold the Set/Resume in either Set or
Resume position until the Check Engine
light begins to flash. Release the switch
when the light begins to flash.
Go to the Fault Code listing. See fault code
list located on the inside of this troubleshooting
guide.
The following illustrates a code flashing sequence
for code 62:
Code Retrieval/ Clearing
1. 6 Flashes
2. Shortpause (1/2sec)
After the Check Engine
the active fault codes and logged codes since powerup are flashed on the Check Engine
If there are no fault codes, a fault code 55 is
Note:
flashed.
ring
Use a Caterpillar-approved diagnostic tool to clear
fault codes.
ault
Codes
3. 2 Flashes
Code
light has been activated, both
light.
System Problem & Fault
1-10
Mack (V-MAC III)
Retrieie
ving V–MAMAC III F
ault
Codes
Code4242
Malfunction Lamp
Clearing Mack Fault Codes
Note:
R
ving
There are twomethods of retrievingthe faultcodes:
Using a MPSI Pro-Link 9000 diagnostic tool to
retrieve active and inactive fault codes.
Manually flashing the active codes on the
Malfunction Lamp
V-MAC Service Diagnostics
1. Key on-wait for two-second power up test
on lamp.
2. Lamp remains on after two-second test if
code is active. Lamp turns off after two
second test if code is inactive.
3. With Cruise ON/OFF switch in OFF position,
press and hold the SET/DECEL switch until the
malfunction lamp goes off for active codes. In active codes must be retreived with Service
Diagnostics.
4. The lamp remains off for one-second then the lamp
begins to flash the two digit blink codes if present.
5. Only one fault code will be blinked pre SET/DECEL
request. Where there are multiple fault codes pre sent, hold in the SET/DECEL switch again until
the lamp goes off. The blinking sequence begins
again for the next code after another one-second
delay.
ault
Codes
using the following procedure:
General Procedures
The followingillustrates a code fla
42:
1. 4 Flashes
2. Short pause (1/2 sec)
3. 2 Flashes
After every complete fault code blinking sequence,
the malfunction lamp returns to normal. It will be
on steady if an active code is still present or turns
OFF if there are no ACTIVE codes.
Note:
flash. Go to fault code listing located in this
troubleshooting guide.
Clearing Mack Fault Codes
Use an MPSI Pro-Link 9000 diagnostic tool to clear
fault codes.
V-MAC Service Diagnostics
shin
gsequenceforcode
Code
If there are no fault codes, no blink codes will
1-11
Driving Techniques
Driving Techniques
Detroit Diesel
Fault Description Generic Fault Codes Type of Code Driving Technique
Codes SID FMI
62 Shift Solenoid
or Lockout
S o l e n oi d
(electrical)
62 Mechanical
System not
Responding
(mechanical)
26,40,53,54,
55,56
26,40,53,54,
55,56
3,4 Component Key on. If the fault code 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.
7 System Operate the vehicle and allow the engine
to perform several Top 2 shifts. If problem occurs and the system has difficulty
performing a Top 2 shift, allow the system to continue the attempt for at least
10 seconds while maintaining shift lever
and throttle positions. After the system
completes the shift attempt, the code
will set.
Cummins
Fault Description Generic Fault Codes Type of Code Driving Technique
Codes SID FMI
536 Lockout
S o l e no i d
40 11 Component Key on. If the fault code 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.
Driving Techniques
537 Shift Solenoid
(electrical)
544 Mechanical
System not
Responding
(mechanical)
51 11
PID
191
7 System Operate the vehicle and allow the engine
to perform several Top 2 shifts. If problem occurs and the system has difficulty
performing a Top 2 shift, allow the system to continue the attempt for at least
10 seconds while maintaining shift lever
and throttle positions. After the system
completes the shift attempt, the code
will set.
1-12
Driving Techniques
Caterpillar (CAT)
Fault Description Generic Fault Codes Type of Code Driving Technique
Codes SID FMI
6 6 S h i f t S o l e n o i d
L o c k o ut
Sol enoi d
(electrical)
67 51 5,6
68 Mechanical
System not
Responding
(mechanical)
40 5,6 Component Key on. If the fault code 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.
PID
191
7 System Operate the vehicle and allow the engine
to perform several Top 2 shifts. If problem occurs and the system has difficulty
performing a Top 2 shift, allow the system to continue the attempt for at least
10 seconds while maintaining shift lever
and throttle positions. After the system
completes the shift attempt, the code
will set.
Mack
Fault Description Generic Fault Codes Type of Code Driving Technique
Codes SID FMI
44 Shift Solenoid
Lockout
Solenoid
( e l e c t r i c a l )
43 11 3,4
38 Mechanical
System not
Responding
(mechanical)
10 3,4 Component Key on. If the fault code is present, the
PID
S32
7 System Operate the vehicle and allow the engine
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.
to perform several Top 2 shifts. If problem occurs and the system has difficulty
performing a Top 2 shift, allow the system to continue the attempt for at least
10 seconds while maintaining shift lever
and throttle positions. After the system
completes the shift attempt, the code
will set.
1-13
Fault Code Isolation
Fault Code Isolation Procedure Index
Detroit Diesel
Fault Description Generic Fault Codes Type of Code Isolation Procedure
Codes SID FMI
62 Shift Solenoid
or Lockout
S o l e no i d
(electrical)
62 Mechanical
System not
Responding
(mechanical)
26,40,53,54,
55,56
26,40,53,54,
55,56
3,4 Component Shift Solenoid or Lockout Solenoid Test
located in this troubleshooting guide.
7 System Mechanical System not Responding
Test located in this troubleshooting
guide.
Cummins
Fault Description Generic Fault Codes Type of Code Isolation Procedure
Codes SID FMI
536 Lockout
S o l e no i d
40 11 Component Shift Solenoid or Lockout Solenoid Test
located in this troubleshooting guide.
Isolation Procedures
537 Shift Solenoid
(electrical)
544 Mechanical
System not
Responding
(mechanical)
51 11
PID
191
7 System Mechanical System not Responding
Test located in this troubleshooting
guide.
1-14
Fault Code Isolation
Caterpillar (CAT)
Fault Description Generic Fault Codes Type of Code Isolation Procedure
Codes SID FMI
66 Shift Solenoid 40 5,6 Component Shift Solenoid or Lockout Solenoid Test
located in this troubleshooting guide.
67 Lockout
Sol enoi d
(electrical)
68 Mechanical
System not
Responding
(mechanical)
51 5,6
PID
191
7 System Mechanical System not Responding
Test located in this troubleshooting
guide.
Mack
Fault Description Generic Fault Codes Type of Code Isolation Procedure
Codes SID FMI
44 Shift Solenoid
43 Lockout
Solenoid
(electrical)
38 Mechanical
System not
Responding
(mechanical)
10 3,4 Component Shift Solenoid or Lockout Solenoid Test
located in this troubleshooting guide.
11 3,4
PID
S32
7 System Mechanical System not Responding
Test located in this troubleshooting
guide.
1-15
Pretest
Pneumatic Pretest
Step A Procedure Condition Action
1. Key off.
2. Install a 0-100 PSI air gauge in
between vehicle supply and
transmission air filter / regulator
supply port (input).
3. Start engine.
4. Allow air pressure to build to
governor cutoff.
5. Read vehicle air
pressure gauge.
If air pressure reads at
least 90 PSI
Go to Step B.
Pneumatic Pretest
If air pressure is below 90
PSI
Repair vehicle air system as
required. Repeat this step.
Step B Procedure Condition Action
1. Key off.
2. Monitor air pressure
on vehicle main air
pressure gauge.
If vehicle maintains air
pressure
Go to Step C.
If vehicle loses air
pressure
Repair leak in vehicle air system.
Repeat this step.
2-1
Pretest
Pneumatic Pretest, continued
Step C Procedure Condition Action
1. Read air pressure
gauge installed in the
air filter/regulator
regulated test port.
If air pressure is 58 to 63
PSI
If air pressure is not 58 to
63 PSI (above or below)
Test complete.
Go to Step D.
Step D Procedure Condition Action
1. Key off.
2. Remove air supply
line to the air filter/
regulator and check
the air flow.
If air flows from the
supply line
If air does not flow from
the supply line
Replace air filter/regulator. Go to
Step C.
Repair vehicle air supply to air filter/
regulator. Go to Step C.
2-2
Pneumatic Pretest, continued
Pretest
Pneumatic Pretest
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2-3
Fault Isolation Procedures
Fault Code: 62 (SID: 26,40,53-56, FMI: 3,4) DDEC III - Shift Solenoid or Lockout Solenoid
Overview
This is an active fault indicating an electrical problem in
the Top 2 shift or lockout solenoid circuit.
Detection
Key on. If active check engine light is on, Top 2 will not
function.
Fallback
Hold current solenoid state or gear until neutral is detected, then manual mode until system powers down.
Required Tools
• Pro-Link 9000 or engine manufacturer scan tool
• Basic hand tools
• Digital Volt/Ohm Meter
• Top 2 Troubleshooting Guide
Possible Causes
This fault can be caused by any of the following:
•Blown fuse
• Electrical open or short in the shift solenoid circuit (solenoid, wiring harness, or connector)
• Damaged vehicle interface harness
• Faulty engine control module (ECM)
1
1. 10 AMP fuse
2. Typical vehicle interface
harness OEM supplied
3. DDEC III ECM OEM supplied
4. Top 2 solenoid valve
2-4
2
4
3
Fault Code Procedures
Fault Code: 62 (SID:26,40,53-56,FMI: 3,4) DDEC III - Shift Solenoid or Lockout Solenoid
Step A Procedure Condition Action
1. Key off.
2. Disconnect three-way
connector from Top 2 solenoid.
3. Measure resistance between
Top 2 valve connector pins:
• A and B (red & blue wires)
•B and C (blue &
white wires)
Note: Some early Top 2 valves
are wired with all blue
wires.
If resistance is 14 to 34
ohms
If resistance is outside of
range
Go to Step B.
Replace Top 2 valve.
Go to Step V.
(SID:26,40,53-56,FMI:3,4)
Fault Code: 62
2-5
Fault Code Procedures
Fault Code: 62 (SID:26,40,53-56,FMI:3,4)
DDEC III - Shift Solenoid or Lockout Solenoid, continued
Step B Procedure Condition Action
1. Measure resistance
between Top 2 valve
connector pin A (red
wire) and ground.
If the resistance is more
than 10K ohms or infinite
If the resistance is less
than 10K ohms
Go to Step C.
Replace the Top 2 valve. Go to
Step V.
2-6
Fault Code Procedures
Fault Code: 62 (SID:26,40,53-56,FMI:3,4)
DDEC III - Shift Solenoid or Lockout Solenoid, continued
Step C Procedure Condition Action
1. Key off.
2. Measure voltage
between vehicle
interface harness
connector pin B and
ground.
If voltage is within 1 volt
of battery voltage
If voltage is outside of
range
Top 2 valve is OK, problem exists in
engine ECM or vehicle harness.
Repair according to vehicle OEM
recommendations. Go to Step V.
Top 2 valve is functioning properly,
problem exists in power supply.
Repair/replace as required. Go to
Step V.
(SID:26,40,53-56,FMI:3,4)
Fault Code: 62
Step V Procedure Condition Action
1. Key off.
2. Reconnect all connectors.
3. Key on.
4. Use Driving Technique to
attempt to reset the code (see
page 1-12).
5. Retrieve fault codes
(see page 1-8).
If no codes Test complete.
If code 62 appears Return to Step A to find error in
testing.
2-7
Fault Isolation Procedures
Fault Code: 537, 536 (SID: 40, 51, FMI: 11) Cummins - Shift Solenoid or Lockout Solenoid
Overview
This is an active fault indicating an electrical problem in
the Top 2 shift or lockout solenoid circuit.
Detection
Key on. If active check engine light is on, Top 2 will not
function.
Fallback
Hold current solenoid state or gear until neutral is detected, then manual mode until system powers down.
Required Tools
• Basic Hand Tools
• Digital Volt/Ohm Meter
• Top 2 Troubleshooting Guide
Possible Causes
This fault can be caused by any of the following conditions:
• Electrical open or short in the shift solenoid circuit
• Damaged vehicle interface harness
• Faulty engine control module (ECM)
1
2
4
1. Typical vehicle interface 4. OEM Supplied
harness OEM supplied 5. Top 2 Solenoid valve
2. Cummins Celect Plus ECM
3. CAT ECM
3
5
2-8
Fault Isolation Procedures
Fault Code: 537, 536 (SID: 40,51, FMI: 11) Cummins - Shift Solenoid or Lockout Solenoid
Step A Procedure Condition Action
1. Key off.
2. Disconnect three-way
connector from Top 2 solenoid.
Fault Code: 537, 536
(SID: 40,51, FMI: 11)
3. Measure resistance
between Top 2 valve
connector pins:
• A and B (red & blue wires)
• B and C (blue & white
wires)
Note: Some early Top 2 valves
are wired with all blue
wires.
If resistance is 14 to 34
ohms
If resistance is outside of
range
Go to Step B.
Replace Top 2 valve. Go to Step
V.
2-9
Fault Isolation Procedures
Fault Code: 537, 536 (SID: 40,51, FMI: 11)
Cummins - Shift Solenoid or Lockout Solenoid, continued
Step B Procedure Condition Action
1. Measure the
resistance between
Top 2 valve connector
pin A (red wire) and
ground.
If resistance is more than
10K ohms or infinite
If resistance is less than
10K ohms
Go to Step C.
Replace Top 2 valve. Go to Step
V.
Step C Procedure Condition Action
1. Key off.
2. Disconnect battery positive (+)
cable.
3. Measure resistance
between vehicle
interface harness
connector pin B and
ground.
If resistance is 0 to .3
ohms
If resistance is outside of
range
Top 2 valve is functioning properly,
problem exists in engine ECM or
vehicle harness. Repair according
to OEM recommendations. Go to
Step V.
Faulty ground. Repair/replace
vehicle interface harness.
2-10
Fault Isolation Procedures
Fault Code: 537, 536 (SID: 40,51, FMI: 11)
Cummins - Shift Solenoid or Lockout Solenoid, continued
Step V Procedure Condition Action
1. Key off.
2. Reconnect all connectors.
3. Key on.
4. Use Driving Technique to
attempt to reset the code (see
page 1-12).
5. Retrieve fault codes
(see page 1-8).
If no codes Test complete.
If code 537 or 536
appears
Return to Step A to find error in
testing.
Fault Code: 537, 536
(SID: 40,51, FMI: 11)
2-11
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