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

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

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

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

ton Service Parts 1 (800) 826-4357

P/N MF-KIT-04

• Shift Lever Tester

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?

Is Top 2 operating

properly?

Retrieve active transmissions codes.

Active transmission

codes?

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?

Symptom?

Test complete.

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

1. 0-100 PSI gauge

2. 5/32" air line

3. 5/32" push-to-connect to 1/8" NPTF

1/8" Air Lines

4. 1/8" nipple

5. 1/8" tee

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

1. 0-100 gauge

2. 5/32" air line

3. 5/32" push-to-connect to 1/8" NPTF

4. Elbow

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

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

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:

earing

Cummins Faulult Cododeses

ode 221

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

Note:

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:

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

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

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

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

PID

191

7 System Operate the vehicle and allow the engine

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

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

This page intentionally left blank

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. 10 AMP fuse

2. Typical vehicle interface harness OEM supplied

3. DDEC III ECM OEM supplied

4. Top 2 solenoid valve

2-4

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. Typical vehicle interface 4. OEM Supplied harness OEM supplied 5. Top 2 Solenoid valve

2. Cummins Celect Plus ECM

3. CAT ECM

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

Fault Isolation Procedures

Fault Code: 66,67 (SID: 40,51, FMI: 5,6) Caterpillar - 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

Hold current solenoid state or gear until neutral is detected, then manual mode until system powers down.

Fallback

Key on. If active check engine light is on, Top 2 will not function.

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:

• Electrical open or short in the shift solenoid circuit (solenoid, wire harness, or connector)

• Damaged vehicle interface harness

• Faulty engine control module (ECM)

1. Typical vehicle interface 4. OEM Supplied harness OEM supplied 5. Top 2 Solenoid valve

2. Cummins Celect Plus ECM

3. CAT ECM

2-12

Fault Isolation Procedures

Fault Code: 66,67 (SID: 40,51, FMI: 5,6) Caterpillar - 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 and 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: 40,51, FMI 5,6)

Fault Code: 66,67

2-13

Fault Isolation Procedures

Fault Code: 66,67 (SID: 40,51, FMI 5,6) Caterpillar - 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, the problem exists in engine ECM or vehicle harness. Repair according to OEM recommendations. Go to Step V.

Faulty ground. Repair/replace vehicle interface harness.

2-14

Fault Isolation Procedures

Fault Code: 66,67 (SID: 40,51, FMI 5,6) Caterpillar - Shift Solenoid or Lockout Solenoid, continued

Step V Procedure Condition Action

1. Key off.

2. Reconnect all connectors.

3. Key on.

4. Use the 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.

(SID: 40,51, FMI 5,6)

Fault Code: 66,67

2-15

Fault Isolation Procedures

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - 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:

• Electrical open or short in the shift solenoid circuit (solenoid, wiring harness, or connector)

• Damaged vehicle interface harness

• Faulty engine control module (ECM)

• Faulty Mack VECU

• Mack 12V supply to Top 2 valve failed (Pin B)

2-16

1. Typical vehicle interface 4. OEM Supplied harness OEM supplied 5. Top 2 Solenoid valve

2. Cummins Celect Plus ECM

3. CAT ECM

Fault Isolation Procedures

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - 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: 10,11, FMI: 3,4)

Fault Code: 44,43

2-17

Fault Isolation Procedures

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - 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 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 voltage is outside of range

Top 2 valve is functioning properly, the problem exists in engine ECM or vehicle harness. Repair according to vehicle OEM recommendations. Go to Step V.

Faulty ground. Repair / replace vehicle interface harness.

2-18

Fault Isolation Procedures

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - 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 44 or 43 appears Return to Step A to find error in

testing.

(SID: 10,11, FMI: 3,4)

Fault Code: 44,43

2-19

Fault Isolation Procedures

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding

Overview

This fault indicates the transmission failed to complete an automatic Top 2 shift as commanded by the engine’s electronic control module (ECM).

Detection

The transmission will make three attempts for the Top 2 to shift. If it fails, the fault is set with check engine light.

Fallback

The transmission will return to manual mode shifting.

Required Tools

• Basic Hand Tools

• Digital Volt/Ohm Meter

• Top 2 Troubleshooting Guide

• Engine Manufacturer Scan Tool

Possible Causes

This fault can be caused by any of the following:

• Low air pressure

• Contaminated air supply

• Faulty Top 2 solenoid valve

• Faulty splitter cylinder

• Loose tone wheel

• Faulty/Contaminated Exhaust Breather

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder

2-20

10 Speed

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder 13 and 18 Speed

Fault Isolation Procedures

(SID: 26,40,53-56, FMI: 7)

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding

Step A Procedure Condition Action

1. Operate the vehicle. Attempt to perform HI to LO and LO to HI split shifts using the splitter button. Note: For Convertible models go directly to Step 2.

2. Confirm AUTO Mode function is working correctly.

Step B Procedure Condition Action

1. Key off.

2. Disconnect Top 2 valve air supply line (S Port).*

If the transmission performs split shifts in all gears except AUTO Mode

If the transmission consistently does not perform split shifts

Go to Step B.

Perform Splitter System Test (see page 3-15). Go to Step V.

Fault Code: 62

3. Connect a 100 psi air gauge to the supply line.

Air pressure 58 to 63 psi Go to Step C.

Air pressure not within 58 to 63 psi

18 Speed Shown

*See Schematic in Appendix for exact location.

Go to Step D.

2-21

Fault Isolation Procedures

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding, continued

Step C Procedure Condition Action

1. Inspect exhaust breather on Top 2 valve for damage or contamination.*

*If unsure breather is faulty, test drive vehicle with breather removed.

If exhaust breather is restricted or Top 2 functions with breather removed

If exhaust breather is fuctioning properly

Replace breather. Go to Step V.

Go to Step E.

Step D Procedure Condition Action

1. Inspect the Top 2 valve air supply fittings and line.

If the fittings and air lines are fuctioning properly

If the fittings and air lines are restricted or damaged

Replace air filter/regulator. Go to Step V.

Repair as necessary. Go to Step V.

Step E Procedure Condition Action

1. Connect engine manufacturer scan tool.

Note: MPSI Pro-Link Scan Tool

with Eaton cartridge may be used on some engines.

2. Disconnect air line from P2 and connect 100 psi air gauge to Top 2 valve P2 port. Leave P1 and supply ports connected.

3. Remove P1 and plug for Convertible.

4. Actuate Shift Solenoid ON (Coil B).

Air pressure 58 to 63 psi Go to Step F.

Air pressure not within 58 to 63 psi

Replace Top 2 valve. Go to Step V.

2-22

Fault Isolation Procedures

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding, continued

Step F Procedure Condition Action

1. Leaving Shift Solenoid ON. Reconnect P1 port for Convertible.

2. Listen for air leaking at Top 2 exhaust breather and Roadranger valve.

Air leaks from one or both

Air does not leak from valve or breather

Step G Procedure Condition Action

1. Leaving 100 psi air gauge connected to P2 port of the Top 2 valve.

2. Move splitter button forward. Note: No action required for Convertibles.

Replace Top 2 valve. Go to Step V.

Go to Step G.

(SID: 26,40,53-56, FMI: 7)

Fault Code: 62

3. Using diagnostic tool actuate Shift Solenoid OFF and Lockout Solenoid ON.

Air pressure gauge reads 0 psi

Air pressure reads above 0 psi

Go to Step H.

Replace Top 2 valve. Go to Step V.

Step H Procedure Condition Action

1. Leave Shift Solenoid OFF and Lockout Solenoid ON.

2. Leave splitter button forward. Note: No action required for Convertibles.

3. Listen for air leaking from Top 2 breather.

Air leaks from breather Replace Top 2 valve.

Go to Step V.

Air does not leak from breather

Go to Step I.

2-23

Fault Isolation Procedures

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding, continued

Step I Procedure Condition Action

1. Disconnect Top 2 valve 3-way connector from vehicle harness.

2. Turn on ignition key.

3. Using MPSI Scan Tool read the Active Fault Codes.

Active Shift or Lockout Solenoid Fault present (see page 1-12).

No Active Fault set Engine ECU not programmed for

Go to Step V.

Top 2. Contact Engine OEM for service. Go to Step V.

Step V Procedure Condition Action

1. Reconnect all air lines and electrical connectors.

2. Start engine.

3. Allow air pressure to build to governor cutoff.

4. Key off.

5. Listen for constant air leaks under the following conditions: Note: Skip the following procedures for Convertibles

• Shift lever in neutral with splitter button back.

2-24

• Shift lever in neutral with splitter button forward.

• Shift lever in 7th/8th gear position.

6. Perform test drive. If there are no constant air leaks and test drive confirms repair

If there are constant leaks or test drive does not confirm vehicle repair

Test complete.

Return to Step A to find error in testing.

Fault Isolation Procedures

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding, continued

(SID: 26,40,53-56, FMI: 7)

Fault Code: 62

This page intentionally left blank

2-25

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding

Overview

This fault indicates the transmission failed to complete an automatic Top 2 Shift as commanded by the engine’s electronic control module (ECM).

Detection

The transmission will make three attempts for the Top 2 to shift. If it fails, the fault is set with check engine light.

Fallback

The transmission will return to manual mode shifting.

Required Tools

• Basic Hand Tools

• Digital Volt/Ohm Meter

• Top 2 Troubleshooting Guide

• Engine Manufacturer Scan Tool

Possible Causes

This fault code can be caused by any of the following:

• Low air pressure

• Contaminated air supply

• Faulty Top 2 solenoid valve

• Faulty splitter cylinder

• Loose tone wheel

• Faulty/Contaminated Exhaust Breather

• Cruise Switch

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder

2-26

10 Speed

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder 13 and 18 Speed

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding

Step A Procedure Condition Action

1. Operate the vehicle. Attempt to perform HI to LO and LO to HI split shifts using the splitter button. Note: For Convertible models go directly to Step 2.

2. Confirm AUTO Mode function is working correctly.

If the transmission performs split shifts in all gears except AUTO Mode

Go to Step B.

(PID: 191, FMI: 7)

Fault Code: 544

If the transmission consistently does not perform split shifts

Perform Splitter System Test on (see page 3-15). Go to Step V.

Step B Procedure Condition Action

1. Key off.

2. Disconnect Top 2 valve air supply line (S Port).*

3. Connect a 100 psi air gauge to the supply line.

Air pressure 58 to 63 psi Go to Step C.

Air pressure not within 58 to 63 psi

Go to Step D.

18 Speed Shown

*See Schematic in Appendix for exact location.

2-27

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding, continued

Step C Procedure Condition Action

1. Inspect exhaust breather on Top 2 valve for damage or contamination.*

*If unsure breather is faulty, test drive vehicle with breather removed.

If exhaust breather is restricted or Top 2 functions with breather removed

If exhaust breather is functioning properly

Replace breather. Go to Step V.

Go to Step E.

Step D Procedure Condition Action

1. Inspect the Top 2 valve air supply fittings and line.

If the fittings and air lines are functioning properly

If the fittings and air lines are restricted or damaged

Replace air filter/regulator. Go to Step V.

Repair as necessary. Go to Step V.

Step E Procedure Condition Action

1. Connect engine manufacturer scan tool.

Note: MPSI Pro-Link Scan Tool

with Eaton cartridge may be used on some engines.

2-28

2. Disconnect air line from P2 and connect 100 psi air gauge to Top 2 valve P2 port. Leave P1 and supply ports connected.

3. Remove P1 and plug for Convertilbe.

4. Actuate Shift Solenoid ON (Coil B).

Air pressure 58 to 63 psi Go to Step F.

Air pressure not within 58 to 63 psi

Replace Top 2 valve. Go to Step V.

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding, continued

Step F Procedure Condition Action

1. Leaving Shift Solenoid ON. Reconnect P1 port for Convetible.

2. Listen for air leaking at Top 2 exhaust breather and Roadranger valve.

Air leaks from one or both

Air does not leak from valve or breather

Replace Top 2 valve. Go to Step V.

Go to Step G.

Step G Procedure Condition Action

1. Leaving 100 psi air gauge connected to P2 Port of the Top 2 valve.

2. Move splitter button forward. Note: No action required for Convertibles.

3. Using diagnostic tool actuate Shift Solenoid OFF and Lockout Solenoid ON.

Air pressure gauge reads 0 psi

Air pressure reads above 0 psi

Go to Step H.

Replace Top 2 valve. Go to Step V.

(PID: 191, FMI: 7)

Fault Code: 544

Step H Procedure Condition Action

1. Leave Shift Solenoid OFF and Lockout Solenoid ON.

2. Leave splitter button forward. Note: No action required for Convertibles.

3. Listen for air leaking from Top 2 breather.

Air leaks from breather Replace Top 2 valve.

Go to Step V.

Air does not leak from breather

Go to Step I.

2-29

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding, continued

Step I Procedure Condition Action

1. Disconnect Top 2 valve 3-way connector from vehicle harness.

2. Turn on ignition key.

3. Using MPSI Scan Tool read the Active Fault Codes.

Active Shift or Lockout Solenoid Fault present (see page 1-12)

No Active Fault set Engine ECU not programmed for

Go to Step V.

Top 2. Contact Engine OEM for service. Go to Step V.

Step V Procedure Condition Action

1. Reconnect all air lines and electrical connectors.

2. Start engine.

3. Allow air pressure to build to governor cutoff.

4. Key off.

5. Listen for constant air leaks under the following conditions: Note: Skip these procedures for Convertibles

• Shift lever in neutral with splitter button back.

2-30

• Shift lever in neutral with splitter button forward.

• Shift lever in 7th/8th gear position.

6. Perform test drive. If there are no constant air leaks and test drive confirms repair

If there are constant leaks or test drive does not confirm vehicle repair

Test complete.

Return to Step A to find error in testing.

Fault Isolation Procedures

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding, continued

(PID: 191, FMI: 7)

Fault Code: 544

This page intentionally left blank

2-31

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI:7) Caterpillar - Mechanical System Not Responding

Overview

This fault code indicates the transmission failed to complete an automatic Top 2 shift as commanded by the engine’s electronic control module (ECM).

Detection

The transmission will make three attempts for the Top 2 to shift. If it fails, the fault is set with check engine light.

Fallback

The transmission will return to manual mode shifting.

Required Tools

• Basic Hand Tools

• Digital Volt/Ohm Meter

• Top 2 Troubleshooting Guide

• Engine Manufacturer Scan Tool

Possible Causes

This fault can be caused by any of the following:

• Low air pressure

• Contaminated air supply

• Faulty Top 2 solenoid valve

• Faulty splitter cylinder

• Loose tone wheel

• Faulty/Contaminated Exhaust Breather

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder

2-32

10 Speed

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder 13 and 18 Speed

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding

Step A Procedure Condition Action

1. Operate the vehicle. Attempt to perform HI to LO and LO to HI split shifts using the splitter button. Note: For Convertible models go directly to Step 2.

2. Confirm AUTO Mode function is working correctly.

If the transmission performs split shifts in all gears except AUTO Mode

If the transmission consistently does not perform split shifts

Go to Step B.

Perform Splitter System Test on (see page 3-15). Go to Step V.

Step B Procedure Condition Action

1. Key off.

2. Disconnect Top 2 valve air supply line (S Port).*

3. Connect a 100 psi air gauge to the supply line.

Air pressure 58 to 63 psi Go to Step C.

Air pressure not within 58 to 63 psi

Go to Step D.

(PID: 191, FMI: 7)

Fault Code: 68

18 Speed Shown

*See Schematic in Appendix for exact location.

2-33

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding, continued

Step C Procedure Condition Action

1. Inspect exhaust breather on Top 2 valve for damage or contamination.*

*If unsure breather is faulty, test drive vehicle with breather removed.

If exhaust breather is restricted or Top 2 functions with breather removed

If exhaust breather is functioning properly

Replace breather. Go to Step V.

Go to Step E.

Step D Procedure Condition Action

1. Inspect the Top 2 valve air supply fittings and line.

If the fittings and air lines are functioning properly

If the fittings and air lines are restricted or damaged

Replace air filter/regulator. Go to Step V.

Repair as necessary. Go to Step V.

Step E Procedure Condition Action

1. Connect engine manufacturer scan tool.

Note: MPSI Pro-Link Scan Tool

with Eaton cartridge may be used on some engines.

2-34

2. Disconnect air line from P2 and connect 100 psi air gauge to Top 2 valve P2 port. Leave P1 and supply ports connected.

3. Remove P1 and plug for Convertible.

4. Actuate Shift Solenoid ON (Coil B).

Air pressure 58 to 63 psi Go to Step F.

Air pressure not within 58 to 63 psi

Replace Top 2 valve. Go to Step V.

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding, continued

Step F Procedure Condition Action

1. Leaving Shift Solenoid ON. Reconnect P1 port for Convertible.

2. Listen for air leaking at Top 2 exhaust breather and Roadranger valve.

Air leaks from one or both

Air does not leak from valve or breather

Replace Top 2 valve. Go to Step V.

Go to Step G.

Step G Procedure Condition Action

1. Leaving 100 psi air gauge connected to P2 Port of the Top 2 valve.

2. Move splitter button forward. Note: No action required for Convertibles.

3. Using diagnostic tool actuate Shift Solenoid OFF and Lockout Solenoid ON.

Air pressure gauge reads 0 psi

Air pressure reads above 0 psi

Go to Step H.

Replace Top 2 valve. Go to Step V.

(PID: 191, FMI: 7)

Fault Code: 68

Step H Procedure Condition Action

1. Leave Shift Solenoid OFF and Lockout Solenoid ON.

2. Leave splitter button forward. Note: No action required for Convertibles.

3. Listen for air leaking from Top 2 breather.

Air leaks from breather Replace Top 2 valve.

Go to Step V.

Air does not leak from breather

Go to Step I.

2-35

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding, continued

Step I Procedure Condition Action

1. Disconnect Top 2 valve 3-way connector from vehicle harness.

2. Turn on ignition key.

3. Using MPSI Scan Tool read the Active Fault Codes.

Active Shift or Lockout Solenoid Fault present (see page 1-12)

No Active Fault set Engine ECU not programmed for

Go to Step V.

Top 2. Contact Engine OEM for service. Go to Step V.

Step V Procedure Condition Action

1. Reconnect all air lines and electrical connectors.

2. Start engine.

3. Allow air pressure to build to governor cutoff.

4. Key off.

5. Listen for constant air leaks under the following conditions: Note: Skip these procedures for Convertibles

• Shift lever in neutral with splitter button back.

2-36

• Shift lever in neutral with splitter button forward.

• Shift lever in 7th/8th gear position.

6. Perform test drive. If there are no constant air leaks and test drive confirms repair

If there are constant leaks or test drive does not confirm vehicle repair

Test complete.

Return to Step A to find error in testing.

Fault Isolation Procedures

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding, continued

(PID: 191, FMI: 7)

Fault Code: 68

This page intentionally left blank

2-37

Fault Isolation Procedures

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding

Overview

This fault indicates the transmission failed to complete an automatic Top 2 shift as commanded by the engines electronic control module (ECM).

Detection

The transmission will make three attempts for the Top 2 to shift. If it fails, the fault is set with check engine light.

Fallback

The transmission will return to manual mode shifting.

Required Tools

• Basic Hand Tools

• Digital Volt/Ohm Meter

• Top 2 Troubleshooting Guide

• Engine Manufacturer Scan Tool

Possible Causes

This fault can be caused by any of the following:

• Low air pressure

• Contaminated air supply

• Faulty Top 2 solenoid valve

• Faulty splitter cylinder

• Loose tone wheel

• Faulty/Contaminated Exhaust Breather

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder

10 Speed

1. Top 2 solenoid valve

2. Air filter/regulator

3. Splitter cylinder 13 and 18 Speed

2-38

Fault Isolation Procedures

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding

Step A Procedure Condition Action

1. Operate the vehicle. Attempt to perform HI to LO and LO to HI split shifts using the splitter button. Note: For Convertible models go directly to Step 2.

2. Confirm AUTO Mode function is working correctly.

Step B Procedure Condition Action

1. Key off.

2. Disconnect Top 2 valve air supply line (S Port).*

If the transmission performs split shifts in all gears except AUTO Mode

If the transmission consistently does not perform split shifts

Go to Step B.

Perform Splitter System Test on (see page 3-15). Go to Step V.

(PID: S32, FMI: 7)

Fault Code: 38

3. Connect a 100 psi air gauge to the supply line.

Air pressure 58 to 63 psi Go to Step C.

Air pressure not within 58 to 63 psi

18 Speed Shown

*See Schematic in Appendix for exact location.

Go to Step D.

2-39

Fault Isolation Procedures

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding, continued

Step C Procedure Condition Action

1. Inspect exhaust breather on Top 2 valve for damage or contamination.*

*If unsure breather is faulty, test drive vehicle with breather removed.

If exhaust breather is restricted or Top 2 functions with breather removed

If exhaust breather is functioning properly

Replace breather. Go to Step V.

Go to Step E.

Step D Procedure Condition Action

1. Inspect the Top 2 valve air supply fittings and line.

If the fittings and air lines are functioning properly

If the fittings and air lines are restricted or damaged

Replace air filter/regulator. Go to Step V.

Repair as necessary. Go to Step V.

Step E Procedure Condition Action

1. Connect engine manufacturer scan tool.

Note: MPSI Pro-Link Scan Tool

with Eaton cartridge may be used on some engines.

2-40

2. Disconnect air line from P2 and connect 100 psi air gauge to Top 2 valve P2 port. Leave P1 and supply ports connected.

3. Remove P1 and plug for Convertible.

4. Actuate Shift Solenoid ON (Coil B).

Air pressure 58 to 63 psi Go to Step F.

Air pressure not within 58 to 63 psi

Replace Top 2 valve. Go to Step V.

Fault Isolation Procedures

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding, continued

Step F Procedure Condition Action

1. Leaving Shift Solenoid ON. Reconnect P1 for Convertible.

(PID: S32, FMI: 7)

Fault Code: 38

2. Listen for air leaking at Top 2 exhaust breather and Roadranger valve.

Air leaks from one or both

Air does not leak from valve or breather

Replace Top 2 valve. Go to Step V.

Go to Step G.

Step G Procedure Condition Action

1. Leaving 100 psi air gauge connected to P2 Port of the Top 2 valve.

2. Move splitter button forward. Note: No action required for Convertibles.

3. Using diagnostic tool actuate Shift Solenoid OFF and Lockout Solenoid ON.

Air pressure gauge reads 0 psi

Air pressure reads above 0 psi

Go to Step H.

Replace Top 2 valve. Go to Step V.

Step H Procedure Condition Action

1. Leave Shift Solenoid OFF and Lockout Solenoid ON.

2. Leave splitter button forward. Note: No action required for Convertibles.

3. Listen for air leaking from Top 2 breather.

Air leaks from breather Replace Top 2 valve.

Go to Step V.

Air does not leak from breather

Go to Step I.

2-41

Fault Isolation Procedures

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding, continued

Step I Procedure Condition Action

1. Disconnect Top 2 valve 3-way connector from vehicle harness.

2. Turn on ignition key.

3. Using MPSI Scan Tool read the Active Fault Codes.

Active Shift or Lockout Solenoid Fault present (see page 1-12)

No Active Fault set Engine ECU not programmed for

Go to Step V.

Top 2. Contact Engine OEM for service. Go to Step V.

Step V Procedure Condition Action

1. Reconnect all air lines and electrical connectors.

2. Start engine.

3. Allow air pressure to build to governor cutoff.

4. Key off.

5. Listen for constant air leaks under the following conditions: Note: Skip these procedures for Convertibles.

• Shift lever in neutral with splitter button back.

2-42

• Shift lever in neutral with splitter button forward.

• Shift lever in 7th/8th gear position.

6. Perform test drive. If there are no constant air leaks and test drive confirms repair

If there are constant leaks or test drive does not confirm vehicle repair

Test complete.

Return to Step A to find error in testing.

Symptom Procedures

Symptom Driven Diagnostics Table

If there are no fault codes present (active or inactive), it may be necessary to determine the cause of the problem on symptoms exhibited by the vehicle. Locate the symptom that best describes the problem in the index below and perform the necessary fault isolation procedure. All procedures can be located inside this troubleshooting guide.

Table 1

Symptom Isolation Procedure

Transmission has an air leak Air Leak Check - 10 Speed Only

Air Leak Check - 13 and 18 Speed Only

Diagnostics Table

Symptom Driven

Splitter shift is not satisfactory (slow, grinding, does not complete)

System attempts Top 2 shift does not complete. All other splitter shifts satisfactory.

Top 2 does not function. No fault set. Engine Programming/Cruise Control, refer to OEM Diagnostics

Splitter System Test

Mechanical System Not Responding Test

DDEC III, Cummins, CAT, and MACK

3-1

Air Leak Test

Fault Isolation Procedures

Overview

This symptom-driven test is performed if the transmission has an air leak and there are no Active or Inactive fault codes.

Detection

There is no detection process specifically for a transmission air leak. 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 mode for a transmission air leak, however, it may effect other vehicle systems.

Required Tools

• Basic Hand Tools

• Troubleshooting Guide

Possible Causes

This symptom can be caused by any of the following:

• Contaminated Air

• Range Valve

• Splitter Valve

• Air Filter/Regulator

• Range Piston / O-ring

3-2

Air filter / regulator

Splitter system

Symptom Procedures

Air Leak Check - T2 Convertible Model Only

Step A Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to

governor cutoff.

3. Place transmission in neutral

and range lever down.

4. Key off.

5. Listen for constant

leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Slave valve

• Air filter/regulator

• Splitter cylinder supply line

• Top 2 valve supply line

If air leaks at the Roadranger valve

If air leaks at the splitter cylinder cover exhaust port

If air leaks at the transmission breather

If air leaks at the Top 2 valve breather

If air leaks at the slave valve

Go to Step B.

Repair fittings or lines as required. Repeat this step.

Convertible Model Only

Air Leak Check - T2

Repair or replace the Roadranger valve as required. Repeat this step.

Replace splitter cover. If problem

persists, repair splitter piston/ cylinder. Repeat this step.

Go to Step D.

Replace Top 2 valve. Repeat this step.

Replace slave valve. Repeat this step.

3-3

Symptom Procedures

Air Leak Check - T2 Convertible Model Only, continued

Step B Procedure Condition Action

1. Use MPSI tool cycle valve Top 2.

Note: High split - no action required.

2. Listen for constant air leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Top 2 ports P1 or P2

• Splitter cylinder signal line

If air leaks at Top 2 valve exhaust port

If air leaks at the splitter cylinder cover exhaust port

If air leaks at transmission breather

Go to Step C.

Repair fittings or lines as required. Repeat this step.

Replace Top 2 valve. Repeat this

step.

Replace splitter insert valve. Repeat this step.

Repair splitter yoke bar O-rings. Repeat this step.

Step C Procedure Condition Action

1. Move range up.

2. Listen for constant air leaks.

If there are no constant air leaks

Test complete.

If air leaks at range actuator valve exhaust port

If air leaks from LO range insert valve

If air leaks from HI range insert valve

Replace range actuator valve. Repeat this step.

Replace LO range insert valve. Repeat this step.

Replace HI range insert valve. Repeat this step.

Step D Procedure Condition Action

1. Move range down.

2. Listen for constant air leaks.

3-4

If the air leak continues or is present at transmission breather

If the air leak stops Test complete.

Repair or replace the range bar O-rings as required. Go to Step V.

Symptom Procedures

Air Leak Check - T2 Convertible Model Only, continued

Step V Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to governor cutoff.

3. Key off

4. Listen for constant air leaks under the following conditions:

• Shift lever in neutral with range button up.

• Shift lever in neutral with range button down. MPSItrigger down.

• Shift lever in 7th/8th gear position.

If there are no constant air leaks

If there are constant air leaks

Test complete.

Convertible Model Only

Air Leak Check - T2

Return to Step A to find error in testing.

3-5

Fault Isolation Procedures

Air Leak Test

Overview

This symptom-driven test is performed if the transmission has an air leak and there are no Active or Inactive fault codes.

Detection

Required Tools

• Basic Hand Tools

• Troubleshooting Guide

Fallback

There is no fallback mode for a transmission air leak, however, it may effect other vehicle systems.

Possible Causes

This symptom can be caused by any of the following:

• Contaminated Air

• Range Valve

• Splitter Valve

• Air Filter/Regulator

• Range Piston / O-ring

3-6

Air filter / regulator

Air Leak Check- 10 Speed Only

Symptom Procedures

Air Leak Check - 10 Speed

Step A Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to governor cutoff.

3. Place transmission in neutral and move splitter button back.

4. Key off.

5. Listen for constant leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Range actuator valve

• Air filter/regulator

• Splitter cylinder supply line

• Top 2 valve supply line

If air leaks at the Roadranger valve

Go to Step B.

Repair fittings or lines as required. Repeat this step.

Repair or replace the Roadranger valve as required. Repeat this step.

Only

If air leaks at the splitter cylinder cover exhaust port

If air leaks at the range actuator valve exhaust port

If air leaks at the LO range insert valve

If air leaks at the transmission breather

If air leaks at the HI range insert valve

Replace splitter cover. If problem persists, repair splitter piston/ cylinder. Repeat this step.

Replace the range actuator valve.

Repeat this step.

Replace the LO range insert valve.

Repeat this step.

Go to Step D.

Go to Step E.

3-7

Symptom Procedures

Air Leak Check- 10 Speed Only, continued

Step B Procedure Condition Action

1. Move splitter button forward.

2. Listen for constant air leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Top 2 ports P1 or P2

• Splitter cylinder signal line

If air leaks at Top 2 valve exhaust port

If air leaks at the splitter cylinder cover exhaust port

Go to Step C.

Repair fittings or lines as required. Repeat this step.

Replace Top 2 valve. Repeat this

step.

Replace splitter insert valve. Repeat this step.

Step C Procedure Condition Action

1. Move shift lever to 7th/8th gear position.

2. Listen for constant air leaks.

If there are no constant air leaks

If air leaks at range actuator valve exhaust port

Test complete.

Replace range actuator valve. Repeat this step.

If air leaks from LO range insert valve

If air leaks from HI range insert valve

Replace LO range insert valve. Repeat this step.

Replace HI range insert valve. Repeat this step.

Step D Procedure Condition Action

1. Move shift lever to 7th/8th gear position.

2. Listen for constant air leaks.

3-8

If the air leak continues Repair or replace the splitter bar

O-rings as required. Go to Step V.

If the air leak stops Repair or replace the range bar

O-rings as required. Go to Step V.

Symptom Procedures

Air Leak Check- 10 Speed Only, continued

Step E Procedure Condition Action

1. Move shift lever to 7th/8th gear position.

2. Listen for constant air leaks.

Step V Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to governor cutoff.

3. Key off

4. Listen for constant air leaks under the following conditions:

If the air leak changes to the LO range insert valve

If the air leak stops or continues from the HI range insert valve

If there are no constant air leaks

Repair the range cylinder and piston as required. Go to Step V.

Replace range insert valves. Go to Step V.

Test complete.

Air Leak Check - 10 Speed

Only

• Shift lever in neutral with splitter button back.

• Shift lever in neutral with splitter button forward.

• Shift lever in 7th/8th gear position.

If there are constant air leaks

Return to Step A to find error in testing.

3-9

Fault Isolation Procedures

Air Leak Test

Overview

This symptom-driven test is performed if the transmission has an air leak and there are no Active or Inactive fault codes.

Detection

Required Tools

• Basic Hand Tools

• Troubleshooting Guide

Fallback

There is no fallback mode for a transmission air leak, however, it may effect other vehicle systems.

Possible Causes

This symptom can be caused by any of the following:

• Contaminated Air

• Range Valve

• Splitter Valve

• Air Filter/Regulator

• Range Piston / O-ring

3-10

Air filter / regulator

Splitter system

Symptom Procedures

Air Leak Check - 13 and 18 Speed Only

Step A Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to governor cutoff.

3. Place transmission in neutral and move splitter button back.

4. Move range lever down.

5. Key off.

6. Listen for constant air leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Range actuator valve

• Air filter/regulator

• Splitter cylinder supply line

• Top 2 valve supply line

If air leaks at the Roadranger valve

If air leaks at the splitter cylinder cover exhaust port

Air Leak Check - 13 and 18

Speed Only

Go to Step B.

Repair fittings or lines as required. Repeat this step.

Repair or replace the Roadranger valve as required. Repeat this step.

Replace splitter cover. If problem

persists, repair splitter piston/ cylinder. Repeat this step.

If air leaks at the slave valve

If air leaks at the transmission breather

Replace the slave valve. Repeat this step.

Go to Step D.

3-11

Symptom Procedures

Air Leak Check - 13 and 18 Speed Only, continued

Step B Procedure Condition Action

1. Move splitter button forward.

2. Listen for constant air leaks.

If there are no constant air leaks

If air leaks from fittings or lines at:

• Top 2 ports P1 or P2

• Splitter cylinder signal line

If air leaks at Top 2 valve exhaust port

If air leaks at the splitter cylinder cover exhaust port

Go to Step C.

Repair fittings or lines as required. Repeat this step.

Replace Top 2 valve. Repeat this

step.

Replace splitter insert valve. Repeat this step.

Step C Procedure Condition Action

1. Move shift lever up.

2. Listen for constant air leaks.

If there are no constant air leaks

If air leaks at slave valve. Replace slave valve. Repeat this

Test complete.

step.

Step D Procedure Condition Action

1. Move shift lever up.

2. Listen for constant air leaks.

3-12

If the air leak continues Repair or replace the splitter bar

O-rings as required. Go to Step V.

If the air leak stops Repair or replace the range bar O-

rings as required. Go to Step V.

Symptom Procedures

Air Leak Check - 13 and 18 Speed Only, continued

Step V Procedure Condition Action

1. Start engine.

2. Allow air pressure to build to governor cutoff.

3. Key off.

4. Listen for constant air leaks under the following conditions:

• Shift lever in neutral with splitter button back.

• Shift lever in neutral with splitter button forward.

If there are no constant air leaks

Test complete.

Air Leak Check - 13 and 18

Speed Only

If there are constant air leaks

Return to Step A to find error in testing.

3-13

Fault Isolation Procedures

Splitter System Test

Overview

This symptom-driven test is completed if the transmission does not perform Splitter Shifts, and there are no active or inactive fault codes.

Detection

The failure is observed by the driver when operating the vehicle. To observe this failure, operate the vehicle and make several shifts up and down across the Splitter.

Fallback

There is no fallback for this symptom.

Required Tools

• Basic Hand Tools

• 0-100 PSI Air Pressure Gauges

• Troubleshooting Guide

Possible Causes

This symptom can be caused by any of the following:

• Low Air Pressure

• Contaminated Air Supply

• Air Leak

• Splitter Valve

• Splitter Actuator / Cylinder / Piston / Yoke

3-14

Air filter / regulator

Splitter system

Symptom Procedures

Splitter System Test

Step A Procedure Condition Action

1. Key off.

2. Place transmission in neutral. Move splitter button back.

3. Locate the signal line from the Top 2 P2 port valve to the splitter cylinder. Tee a 0-100 PSI air pressure gauge into the line at the splitter cylinder cover.

4. Move the splitter button forward and back. Observe the pressure gauge.

If the pressure rapidly rises to regulated pressure when the button is forward and

Pressure rapidly decreases when the button is back

If the pressure does not reach regulated pressure or pressure does not change rapidly

Go to Step E.

Splitter System Test

Go to Step B.

3-15

Symptom Procedures

Splitter System Test, continued

Step B Procedure Condition Action

1. Remove gauge from Top 2 valve signal line.

2. Locate the signal line from the Roadranger valve to the Top 2 valve P1 port. Tee the pressure gauge into the signal line at the Top 2 valve.

3. Move the splitter button forward and back. Observe the pressure gauge.

If the pressures rapidly rises to regulated pressure when the button is forward and

Pressure rapidly decreases when the button is back

If the pressure does not reach regulated pressure or pressure does not change rapidly

Go to Step C.

Go to Step D.

Step C Procedure Condition Action

3-16

1. Inspect fittings and air lines at port P1 and P2 or the Top valve.

2. Inspect signal line fittings and air line between Top 2 valve and splitter cylinder.

If the fittings and air lines are functioning properly

If the fittings and air lines are restricted

Replace Top 2 valve. Go to Step V.

Repair or replace as necessary. Go to Step V.

Symptom Procedures

Splitter System Test, continued

Step D Procedure Condition Action

1. Inspect fittings and air lines between the:

• Top 2 valve and Roadranger valve

• Roadranger valve, range actuator valve, and air filter/regulator

If the fittings and air lines are functioning properly

Replace Roadranger valve. Go to Step V.

Repair as necessary. Go to Step V.

Step E Procedure Condition Action

1. Locate the supply line between the splitter cylinder and air filter/ regulator. Tee a 0-100 PSI air gauge into the line at the splitter cylinder.

2. Observe the pressure gauge.

If the pressure is 55 to 65 PSI

If the pressure is not 55 to 65 PSI

Go to Step G.

Go to Step F.

Splitter System Test

Step F Procedure Condition Action

1. Inspect supply fittings and air lines between the splitter cylinder and the air filter/ regulator.

If the fittings and air lines are functioning properly

If the fittings and air lines are restricted

Replace air filter/regulator. Go to Step V.

Repair as necessary. Go to Step V.

3-17

Symptom Procedures

Splitter System Test, continued

Step G Procedure Condition Action

1. Hold the spool valve down.

Note: Use a small screwdriver

through the signal line opening.

10 Speed Only

Note: Blow shop air into signal

line opening with a rubber tip air gun.

If air does not exhaust when the insert valve is pushed in and

Air briefly exhaust when the insert valve is let out

If air does not exhaust as indicated above

If air briefly exhausts when shop air is applied

Go to Step I.

Go to Step H.

Go to Step I.

13 and 18 Speed Only

Note: Spool Valve Cylinder

Only: Through the signal line opening use a small screwdriver to push in the spool valve. Valve travels approximately 1/4 inch.

Air does not exhaust when shop air is applied

If splitter shifts Replace spool valve. Go to Step V.

If splitter does not shift Go to Step J.

Go to Step H.

3-18

Symptom Procedures

Splitter System Test, continued

Step H Procedure Condition Action

1. Inspect the exhaust port and insert valve for contamination.

If exhaust port and insert valves are functioning properly

If contamination is found Repair or replace as needed. Go to

Replace the insert valve. Go to Step V.

Step V.

Step I Procedure Condition Action

1. Remove the splitter cylinder cover.

2. Inspect gasket. If the gasket is installed

correctly

If the gasket is not installed correctly

Remove the auxiliary section and repair as required. Go to Step V.

Repair as required. Go to Step V.

Step J Procedure Condition Action

1. Spool Valve Cylinder Only: Remove exhaust breather on cylinder top.

2. Push in the spool valve with a small screwdriver through the signal line.

If splitter shifts Replace breather. Go to Step V.

Splitter System Test

If splitter does not shift Replace spool valve. Go to Step

3-19

Symptom Procedures

Splitter System Test, continued

Step V Procedure Condition Action

1. Move the splitter button forward and back. Observe the pressure gauge.

If the pressure rapidly rises to regulate pressure when the button is forward and

Pressure rapidly decreases when the button is back

If the pressure does not reach regulated pressure or pressure does not change rapidly

Test complete.

Go to Step B.

3-20

Service Information

This appendix section provides helpful background information on the Top 2 system.

Major topics:

• 9 speed convertible overview

• 10 speed overview

• 13 speed overview

• 18 speed overview

• Splitter cylinder operation - 10 speed only (old design)

• Splitter cylinder insert valve operation -10 speed only (old design)

• Splitter cylinder operation - 10 speed only (latest design)

• Splitter cylinder spool valve operation - 10 speed only (latest design)

• Splitter cylinder - 13 and 18 speed (old design)

• Insert valve - 13 and 18 speed (old design)

• Splitter cylinder - 13 and 18 speed only (latest design)

• Spool valve - 13 and 18 speed (latest design)

• Suggested test fixtures

Service Information

A-1

Service Information

Top 2 System Overview - 9 Speed Convertible Only

Here is a schematic showing the components, air connectors, and air flow between the Top 2 Convertible components under different gears.

A-2

Lock High

Except During

Top 2 Function

Service Information

Top 2 System Overview - 10 Speed Only

The Eaton Fuller Top 2 is an add-on system to the Super 10 heavy-duty transmission. By itself, the Super 10 is a manually operated transmission. When equipped with the Top 2 system; however, the Super 10 provides automatic shifting functions between the top two gears.

The following figure highlights the components and features of the Top 2 system.

Top 2 System Overview

1. Range actuator valve - automatically activate LO and HI range

2. Top 2 solenoid valve - automatically shifts between the Top 2 gears

3. Roadranger valve - shifts transmission to the six gear positions

4. Range cylinder - shifts transmission between LO and HI range

5. Air filter/regulator

6. Splitter cylinder - shifts transmission between odd/even numbered gear positions

A-3

Service Information

Top 2 System Overview - 10 Speed Only (continued)

Here is a schematic showing the components, air connectors, and air flow between the Top 2 components under different gears.

A-4

Service Information

Top 2 System Overview - 13 Speed Only

The Eaton Fuller Top 2 is an add-on system to the Super 13 heavy duty transmission. By itself, the Super 13 is a manually operated transmission. When equipped with the Top 2 system; however, the Super 13 provides automatic shifting functions between the top two gears.

The following figure highlights the components and features of the Top 2 system.

Top 2 System Overview

1. Slave Valve - directs air to the range cylinder

2. Top 2 solenoid valve - automatically shifts between the Top 2 gears

3. Roadranger valve - shifts transmission to the six gear positons

4. Range cylinder - shifts transmission between LO and HI range

5. Air Filter/ regulator

6. Splitter cylinder - shifts transmission between odd/even numbered gear positions

A-5

Service Information

Top 2 System Overview - 13 Speed Only (continued)

Here is a schematic showing the components, air connectors, and air flow between the Top 2 components under different gears.

A-6

Service Information

Top 2 System Overview - 18 Speed Only

The Eaton Fuller Top 2 is an add-on system to the Super 18 heavy-duty transmission. By itself, the Super 18 is a manually operated transmission. When equipped with the Top 2 system; however, the Super 18 provides automatic shifting functions between top two gears.

The following figure highlights the components and features of the Top 2 System.

Top 2 System Overview

1. Slave valve - directs air to the range cylinder

2. Top 2 solenoid valve- automatically shifts between the Top 2 gears

3. Roadranger valve - shifts transmission to the six gear positions

4. Range cylinder - shifts transmission between LO and HI range

5. Air filter/regulator

6. Splitter cylinder - shifts transmission between odd/even numbered gear positions

A-7

Service Information

Top 2 System Overview - 18 Speed Only (continued)

Here is a schematic showing the components, air connector, and air flow between the Top 2 components under different gears.

A-8

Service Information

Splitter Cylinder Assembly - 10 Speed Only (old design)

1, 3, 5, 7 Gear Positions

With the Roadranger valve button in the rearward position, no air is supplied to the splitter cylinder cover port (1), moving the piston rearward, disengaging splitter gearing (2).

2, 4, 6, 8 Gear Positions

With the Roadranger valve button in the forward position, air is supplied to the splitter cylinder cover port (1), moving the piston forward, engaging splitter gearing (2).

Splitter Cylinder Assembly

A-9

Service Information

Insert Valve

LO Split

The insert valve is a self contained13/16" valve assembly located in the splitter cylinder cover. It cannot be disassembled except for the three o-rings on the outer diameter. The o-rings provide a stationary seal and do not move in the cylinder.

1. From piston backside, yoke bar rearward

2. No air on signal line

3. Exhaust

4. Constant air sealed off at this point

HI Split

Insert valve piston travel is only 1/32". When no air is applied to the valve piston top side through the signal line, constant air from he air filter/regulator moves the yoke bar rearward. This engages the rear auxiliary drive gear (LO and HI split direct) while air is exhausted out the insert valve.

1. From piston backside, yoke bar forward

2. Air on signal line

3. Constant air sealed off at this point

4. Constant air

When air is applied to the valve piston top side, the piston moves down, passing air through the insert valve bottom to the cylinder piston front and backside. This air moves the yoke par forward to engage the front auxiliary drive gear (LO and HI split overdrive).

A-10

Service Information

Splitter Cylinder Assembly - RTL-XX710 Model (latest design)

Odd Numbered Gear Positions (1,3,5,7,9)

With the Roadranger valve button in the rearward position, no air is supplied to the splitter piston rear, moving the piston rearward.

Even Numbered Gear Positions (2,4,6,8,10)

With the Roadranger valve button in the forward position, air is supplied to the splitter piston rear, forcing the piston forward.

Splitter Cylinder Assembly

A-11

Service Information

Spool Valve

LO Range and HI Range High Split

The spool valve components shown are part of a self-contained valve assembly, part number A-6861.

The spool valve piston travel is approximately 1/2". When no air is supplied from the Roadranger valve to the valve spool left side (1), constant air from the filter/regulator (2) is supplied to the splitter cylinder piston rear side moving the yoke bar forward. Air is exhausted from the splitter cylinder front (3) and from the breather situated on the valve assembly rear.

1. No air on signal line

2. Constant air from air filter/regulator

3. Splitter cylinder front

4. To piston front

5. To piston rear, yoke bar forward

LO Range and HI Range Low Split

1. Air on signal line

2. Constant air from air filter/regulator

3. Splitter cylinder rear

4. To piston front, yoke bar rearward

5. Exhaust from rear side of cylinder

A-12

Service Information

Splitter Cylinder Assembly - RTLO-XX713 and XX718 (old design)

LO Split

With the splitter button in the rearward position, no air is supplied to the splitter cylinder cover top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, engaging the auxiliary drive gear (3).

HI Split

With the splitter button in the forward position, air is supplied to the splitter cylinder cover top port (1), moving the splitter piston rearward, engaging the splitter gear (2).

Splitter Cylinder Assembly

A-13

Service Information

Insert Valve

LO Range and HI Range LO Split

The insert valve is a self contained 13/16" valve assembly located in the intermediate shift splitter cylinder cover. It cannot be disassembled except for the three o-rings on the outer diameter. The o-rings provide a stationary seal and do not move in the cylinder.

Insert valve piston travel is only 1/32". When no air is applied to the valve piston top side, constant air supplied from the air filter/ regulator passes freely through the insert valve and to the cylinder piston backside, moving the yoke bar forward to disengage the rear auxiliary drive gear (LO range and HI range Low split).

1. To piston backside, yoke bar forward

2. No air on signal line

3. Constant air

A-14

Service Information

LO Range (18 Speed Only) and HI Range HI Split

When air is applied to the valve piston top side through the signal line, the piston moves down to cut off air supplied to the cylinder piston backside. This air is exhausted out the cover bottom port as constant air supplied from the regulator is directed to the cylinder piston front side, moving the yoke bar rearward to engage the rear auxiliary drive gear (LO range [18 Speed Only] and HI range HI split).

1. From piston backside, yoke bar rearward

2. Air on signal line

3. Constant air sealed off at the point

4. Exhaust

When air is applied to the valve piston top side, the piston moves down, passing air through the insert valve bottom to the cylinder piston front and backside. This air moves the yoke bar forward to engage the front auxiliary drive gear (LO and HI split overdrive).

Splitter Cylinder Assembly

A-15

Service Information

Splitter Cylinder Assembly - RTLO-XX710 Model (latest design)

Odd Numbered Gear Positions (1, 3, 5, 7, 9)

With the Roadranger valve button in the forward postion, air is supplied to the splitter cylinder cover port (1), moving the piston rearward, disengaging splitter gearing (2).

Even Numbered Gear Positions (2, 4, 6, 8, 10)

With the Roadranger valve button in the rearward position, no air is supplied to the splitter cylinder cover port, moving the piston forward, engaging splitter gearing (2).

A-16

Service Information

Spool Valve

LO Range and HI Range HI Split

The spool valve components shown are part of a self-contained valve assembly, part number A-6862.

1. No air on signal line

2. Constant air from air filter/ regulator

3. Splitter cylinder front

4. To piston front

5. To piston rear, yoke bar forward

LO Range and HI Range LO Split

When air is supplied from the Roadranger valve to the valve spool left side (1), constant air from the filter/ regulator (2) is supplied to the splitter cylinder piston front side moving the yoke bar rearward. Air is exhausted from the splitter cylinder rear (3) and from the breather situated on the valve assembly rear.

Splitter Cylinder Assembly

1. Air on signal line

2. Constant air from air filter/ regulator

3. Splitter cylinder rear

4. To piston front, yoke bar rearward

5. Exhaust from rear side of cylinder

A-17

Service Information

Splitter Cylinder Assembly - RTLO-XX913 and XX918 (latest design)

LO Range or HI Range LO Split

With the splitter control button in the rearward position, no air is supplied to the splitter cylinder cover top port (1). The constant air from the air filter/regulator assembly (2) moves the splitter piston forward, disengaging the rear auxiliary drive gear (3).

LO Range (18 Speed only) or HI Range HI Split

With the splitter control button in the forward position, air is supplied to the splitter cylinder cover top port (1), moving the splitter piston rearward, engaging the rear auxiliary drive gear (2).

A-18

Service Information

Spool Valve

LO Range and HI Range LO Split

The spool valve components shown are part of a self-contained valve assembly, part number A-6862.

1. No air on signal line

2. Constant air form air filter/regulator

3. Splitter cylinder front

4. To piston front

5. To piston rear, yoke bar forward

LO Range (18 Speed only) and HI Range HI Split

Splitter Cylinder Assembly

1. Air on signal line

2. Constant air form air filter/regulator

3. Splitter cylinder rear

4. To piston front, yoke bar rearward

5. Exhaust from rear side of cylinder

A-19

Eaton Transmission RTLO-16618A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Warnings

Introduction

Diagnostic Procedure

Suggested Test Fixures

Top 2 Basic Operation and Overview

System Problem

Driving Techniques

Fault Code Isolation Procedure Index

Pneumatic Pretest

Fault Code: 62 (SID: 26,40,53-56, FMI: 3,4) DDEC III - Shift Solenoid or Lockout Solenoid

Fault Code: 62 (SID:26,40,53-56,FMI: 3,4) DDEC III - Shift Solenoid or Lockout Solenoid

Fault Code: 537, 536 (SID: 40, 51, FMI: 11) Cummins - Shift Solenoid or Lockout Solenoid

Fault Code: 537, 536 (SID: 40,51, FMI: 11) Cummins - Shift Solenoid or Lockout Solenoid

Fault Code: 66,67 (SID: 40,51, FMI: 5,6) Caterpillar - Shift Solenoid or Lockout Solenoid

Fault Code: 66,67 (SID: 40,51, FMI: 5,6) Caterpillar - Shift Solenoid or Lockout Solenoid

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - Shift Solenoid or Lockout Solenoid

Fault Code: 44,43 (SID: 10,11, FMI: 3,4) MACK - Shift Solenoid or Lockout Solenoid

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding

Fault Code: 62 (SID: 26,40,53-56, FMI: 7) DDEC III - Mechanical System Not Responding

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding

Fault Code: 544 (PID: 191, FMI: 7) Cummins - Mechanical System Not Responding

Fault Code: 68 (PID: 191, FMI:7) Caterpillar - Mechanical System Not Responding

Fault Code: 68 (PID: 191, FMI: 7) Caterpillar - Mechanical System Not Responding

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding

Fault Code: 38 (PID: S32, FMI: 7) MACK - Mechanical System Not Responding

Symptom Driven Diagnostics Table

Air Leak Test

Air Leak Check - T2 Convertible Model Only

Air Leak Test

Air Leak Check- 10 Speed Only

Air Leak Test

Air Leak Check - 13 and 18 Speed Only

Splitter System Test

Splitter System Test

Service Information

Top 2 System Overview - 9 Speed Convertible Only

Splitter Cylinder Assembly - 10 Speed Only (old design)

Splitter Cylinder Assembly - RTL-XX710 Model (latest design)

Splitter Cylinder Assembly - RTLO-XX713 and XX718 (old design)

Splitter Cylinder Assembly - RTLO-XX710 Model (latest design)

Splitter Cylinder Assembly - RTLO-XX913 and XX918 (latest design)