Eaton Transmission RTLO-16618A Service Manual

Troubleshooting Guide

Fuller Transmissions

TRTS0070

October 2007

RTLO-11610B	RTLO-16618A	RTLOC-16909A-T2	RTLOF-16618A
RTLO-11610B-T2	RTLO-16713A	RTLOF-11610B	RTLOF-16713A
RTLO-12610B	RTLO-16713A-T2	RTLOF-11610B-T2	RTLOF-16713A-T2
RTLO-12610B-T2	RTLO-16718B	RTLOF-12610B	RTLOF-16718B
RTLO-12713A	RTLO-16913A	RTLOF-12610B-T2	RTLOF-16913A
RTLO-12913A	RTLO-16913A-T2	RTLOF-12713A	RTLOF-16913A-T2
RTLO-13610B	RTLO-16918B	RTLOF-12913A	RTLOF-16918B
RTLO-13610B-T2	RTLO-16918B-T2	RTLOF-13610B	RTLOF-16918B-T2
RTLO-14610A	RTLO-17610B	RTLOF-13610B-T2	RTLOF-17610B
RTLO-14610B	RTLO-17610B-T2	RTLOF-14610B	RTLOF-17610B-T2
RTLO-14610B-T2	RTLO-18610B	RTLOF-14610B-T2	RTLOF-18610B
RTLO-14613B	RTLO-18610B-T2	RTLOF-14613B	RTLOF-18718B
RTLO-14618A	RTLO-18718B	RTLOF-14618A	RTLOF-18913A
RTLO-14713A	RTLO-18718B-T2	RTLOF-14713A	RTLOF-18913A-T2
RTLO-14718B	RTLO-18913A	RTLOF-14718B	RTLOF-18918B
RTLO-14913A	RTLO-18913A-T2	RTLOF-14913A	RTLOF-18918B-T2
RTLO-14918B	RTLO-18918B	RTLOF-14918B	RTLOF-20913A
RTLO-14918B-T2	RTLO-18918B-T2	RTLOF-14918B-T2	RTLOF-20918B
RTLO-15610B	RTLO-20913A	RTLOF-15610B	RTLOF-20918B-T2
RTLO-15610B-T2	RTLO-20918B	RTLOF-15610B-T2	RTLOF-22918B
RTLO-16610B	RTLO-20918B-T2	RTLOF-16610B	RTLOFC-16909A-T2
RTLO-16610B-T2	RTLO-22918B	RTLOF-16610B-T2

For parts or service call us Pro Gear & Transmission, Inc.

1(877) 776-4600

[phone] [e-mail]

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

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

1.Place shift lever in neutral

2.Set parking brake

3.Block wheels

Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.

When parking the vehicle or leaving the cab:

1.Place shift lever in neutral

2.Set the parking brake

Do not operate if alternator lamp is lit or if gauges indicate low voltage.

Battery (+) and (-) must be disconnected prior to any type of welding on the vehicle.

Suggested Tools:

•Volt/Ohm Meter

SPX / Kent-Moore 1 [phone]

P/N 5505027

•PC-based Service Tool “Service Ranger” Contact your OEM

•Data Link Tester

Eaton Service Parts 1 [phone]

P/N MF-KIT-04

•Shift Lever Tester

Eaton Service Parts 1 [phone]

P/N 691795

•Eaton Test Adapter Kit

SPX / Kent-Moore 1 [phone]

P/N J-43318

•6-Pin Deutsch Diagnostic Adapter

SPX / Kent-Moore 1 [phone]

P/N J-38500-60A

For information and assistance, call the Roadranger Help Desk at 1-800-826-HELP (4357) (Mexico: 01-800 826-HELP (4357). You may also find more information about Eaton Fuller Transmissions at www.Roadranger.com.

Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided.

Table of Contents

	Introduction		FaultCode: 38
	Introduction ............................................................	1-1	(PID: S32, FMI: 7)
	Diagnostic Procedure .............................................	1-2	MACK - Mechanical System Not
			Responding ...................................................	2-38
	Suggested Test Fixures		Symptom Procedures
	Suggested Test Fixures ..........................................	1-3
			Symptom Driven Diagnostics Table ........................	3-1
	General Procedures		Air Leak Test - T2 Convertible Only .........................	3-2
	Top 2 Basic Operation and Overview	1-5	Air Leak Test - 10 Speed Onoy.................................	3-6
			Air Leak Test - 13 and 18 Speed Only	3-10
	System Problem	1-8
			Splitter System Test	3-14

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

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

Contents of Table

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					• Diagnose and repair active engine
					codes per OEM recommendations.
codes?			YES		• Clear active and inactive codes
					with MPSI scan tool.
					• Test drive and confirm
NO					vehicle repair.
Is Top 2 operating
properly?			YES
		NO

Retrieve active transmissions codes.

					•	Perform Electrical Pretest.
Active transmission					•	Refer to the Fault Code Isolation
codes?			YES			Procedure Index to select a Fault
						Code Isolation Procedure.
NO
Retrieve Inactive Codes.

Inactive Codes?

YES

NO

Symptom?

YES

NO

•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.

Test complete.

Procedure Diagnostic

1-2

Suggested Test Fixures

Suggested Test Fixures

Note: Only one gauge required.

Range Cylinder

2 1

3

		5
			4
1.	0-100 PSI gauge	4.	1/8" nipple
2.	5/32" air line	5.	1/8" tee
3.	5/32" push-to-connect to 1/8" NPTF

1/8" Air Lines

	1		2
			3
			4
	6		5
			7	8
				9
1.	0-100 PSI gauge	5.	1/8" tee
2.	5/32" air line	6.	Elbow assembly
3.	5/32" push-to-connect to 1/8" NPTF	7.	1/8" air line
4.	Elbow	8.	Grip nut
		9.	Compression sleeve

1-3

Suggested Test Fixures

5/32" Air Lines

			2
	1
			3
			4
	6		5
			7	8
				9
1.	0-100 gauge	5.	1/8" Tee
2.	5/32" air line	6.	Elbow assembly
3.	5/32" push-to-connect to 1/8" NPTF	7.	5/32" air line
4.	Elbow	8.	Grip nut
		9.	Compression sleeve

Fixures Test Suggested

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

General Procedures

	Driving Tips				Top
					2
	• When the transmission is making a shift in the AUTO Mode, depressing the clutch pedal or moving the lever into the			Overview	OperationBasic
	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				and
	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.

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 synchro-
	nous, 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

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

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.

Code

FMI

FaultCode 62Shorted Circuit

3

Fault Code 62Open Circuit

4

Fault Code 62Mechanical System Not

7

Responding

Flash codes may be retrieved by manually flashing the codes 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.

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.

Fault & Problem System

Clearing Retrieval/ Code

1-8

General Procedures

Cummins

Retrieving Cummins Fault 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 and Warning lights on the cab panel using the following procedure:

1.Key off.

2.Turn the Diagnostic switch on or connect the shorting plug to the diagnostic connector.

3.Key on.

After the lights have been activated, the lights will continue to flash the same color.

To move to the next code: Move the Idle Speed Adjust switch to the + position.

To move to the previous code:: Move the Idle Speed Adjust switch to the-position.

NOTE: If there are no active fault codes bothlights will come on and stay on.

Go to the Fault code listing. See fault code list located inside this troubleshooting guide.

The following illustrates a code flashingsequence for a code 221:

Clearing Cummins Fault Codes

Use a Cummins-approveddiagnostic tool to clear fault codes.

1.	1	Flash												6.			Short pause (1 or 2 sec)
2. Short pause (2 sec)														7.			1 Flash
3. 2		Flashes												8.			Short pause (1 or 2 sec)
4. Short pause (1 or 2 sec)														9.			1 Flash
5. 2		Flashes

Code 221

1-9

Fault Isolation Procedures

Caterpillar (CAT)

Retrieving CAT Fault Codes

There are two methods of retrieving the fault codes:

Using a 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:

1.

6 Flashes

3. 2 Flashes

2. Shortpause (1/2sec)

Code 62

After the Check Engine light has been activated, both the active fault codes and logged codes since powerup are flashed on the Check Engine light.

Note: If there are no fault codes, a fault code 55 is flashed.

Clearing CAT Fault Codes

Use a Caterpillar-approved diagnostic tool to clear fault codes.

Fault & Problem System

Clearing Retrieval/ Code

1-10

General Procedures

Mack (V-MAC III)

Retrieving V–MAC III Fault Codes

There are twomethods of retrieving the fault codes: Using a MPSI Pro-Link 9000 diagnostic tool to

retrieve active and inactive fault codes.

Manually flashing the active codes on the Malfunction Lamp using the following procedure: 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. Inactive 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 present, 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.

The followingillustrates a code flashing sequencefor code 42:

1.4 Flashes

2.Short pause (1/2 sec)

3.2 Flashes

Code 42

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: If there are no fault codes, no blink codes will 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

1-11

Driving Techniques

Driving Techniques

Detroit Diesel

Fault	Description	Generic Fault Codes		Type of Code	Driving Technique
Codes		SID	FMI
62	Shift Solenoid	26,40,53,54,	3,4	Component	Key on. If the fault code is present, the
	or Lockout	55,56			system should automatically detect the
	Solenoid				problem and set the code. If the fault is
	(electrical)				not present at key on, operate the vehicle
					and attempt to duplicate the driving con-
					ditions that triggered the fault code. Pos-
					sible triggers include heat and vibration.
62	Mechanical	26,40,53,54,	7	System	Operate the vehicle and allow the engine
	System not	55,56			to perform several Top 2 shifts. If prob-
	Responding				lem occurs and the system has difficulty
	(mechanical)				performing a Top 2 shift, allow the sys-
					tem 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	40	11	Component	Key on. If the fault code is present, the
	Solenoid				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 con-
					ditions that triggered the fault code. Pos-
					sible triggers include heat and vibration.
537	Shift Solenoid	51	11
	(electrical)
544	Mechanical	PID	7	System	Operate the vehicle and allow the engine
	System not	191			to perform several Top 2 shifts. If prob-
	Responding				lem occurs and the system has difficulty
	(mechanical)				performing a Top 2 shift, allow the sys-
					tem 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.

Techniques Driving

1-12

Driving Techniques

Caterpillar (CAT)

Fault	Description	Generic Fault Codes		Type of Code	Driving Technique
Codes		SID	FMI
66	ShiftSolenoid	40	5,6	Component	Key on. If the fault code is present, the
					system should automatically detect the
	Lockout				problem and set the code. If the fault is
	Solenoid				not present at key on, operate the vehicle
	(electrical)				and attempt to duplicate the driving con-
					ditions that triggered the fault code. Pos-
					sible triggers include heat and vibration.
67		51	5,6
68	Mechanical	PID	7	System	Operate the vehicle and allow the engine
	System not	191			to perform several Top 2 shifts. If prob-
	Responding				lem occurs and the system has difficulty
	(mechanical)				performing a Top 2 shift, allow the sys-
					tem 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	10	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
	Lockout				and attempt to duplicate the driving con-
	Solenoid				ditions that triggered the fault code. Pos-
	(electrical)				sible triggers include heat and vibration.
43		11	3,4
38	Mechanical	PID	7	System	Operate the vehicle and allow the engine
	System not	S32			to perform several Top 2 shifts. If prob-
	Responding				lem occurs and the system has difficulty
	(mechanical)				performing a Top 2 shift, allow the sys-
					tem 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	26,40,53,54,	3,4	Component	Shift Solenoid or Lockout Solenoid Test
	or Lockout	55,56			located in this troubleshooting guide.
	Solenoid
	(electrical)
62	Mechanical	26,40,53,54,	7	System	Mechanical System not Responding
	System not	55,56			Test located in this troubleshooting
	Responding				guide.
	(mechanical)

Cummins

Fault	Description	Generic Fault Codes		Type of Code	Isolation Procedure
Codes		SID	FMI
536	Lockout	40	11	Component	Shift Solenoid or Lockout Solenoid Test
	Solenoid				located in this troubleshooting guide.
537	Shift Solenoid	51	11
	(electrical)
544	Mechanical	PID	7	System	Mechanical System not Responding
	System not	191			Test located in this troubleshooting
	Responding				guide.
	(mechanical)

Procedures Isolation

1-14

Fault Code Isolation

Caterpillar (CAT)

Fault	Description	Generic Fault Codes		Type of Code	Isolation Procedure
Codes		SID	FMI
66	ShiftSolenoid	40	5,6	Component	Shift Solenoid or Lockout Solenoid Test
					located in this troubleshooting guide.
67	Lockout	51	5,6
	Solenoid
	(electrical)
68	Mechanical	PID	7	System	Mechanical System not Responding
	System not	191			Test located in this troubleshooting
	Responding				guide.
	(mechanical)

Mack

Fault	Description	Generic Fault Codes		Type of Code	Isolation Procedure
Codes		SID	FMI
44	Shift Solenoid	10	3,4	Component	Shift Solenoid or Lockout Solenoid Test
					located in this troubleshooting guide.
43	Lockout	11	3,4
	Solenoid
	(electrical)
38	Mechanical	PID	7	System	Mechanical System not Responding
	System not	S32			Test located in this troubleshooting
	Responding				guide.
	(mechanical)

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

If air pressure reads at

Go to Step B.

pressure gauge.

least 90 PSI

If air pressure is below 90

Repair vehicle air system as

PSI

required. Repeat this step.

Pretest Pneumatic

Step B		Procedure					Condition			Action
1.		Key off.
2.		Monitor air	pressure		If	vehicle	maintains	air		Go to Step C.
		on vehicle	main air		pressure
		pressure gauge.
					If	vehicle	loses	air		Repair leak in vehicle air system.
					pressure					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		Test complete.
PSI

If air pressure is not 58 to 63 PSI (above or below)

Go to Step D.

Step D		Procedure				Condition		Action
1.		Key off.
2.		Remove	air	supply		If air flows from the		Replace air filter/regulator. Go to
		line to the air filter/				supply line		Step C.
		regulator	and	check
		the air flow.

If air does not flow from the supply line

Repair vehicle air supply to air filter/ regulator. Go to Step C.

2-2

Pretest

Pneumatic Pretest, continued

Pretest Pneumatic

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

2

1.	10 AMP fuse
																										4
2.	Typical vehicle interface
	harness OEM supplied									3

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	If resistance is 14 to 34		Go to Step B.
Top 2 valve connector pins:	ohms

•A and B (red & blue wires)

•B and C (blue &

white wires)

Note: Some early Top 2 valves

If resistance is outside of

Replace Top 2 valve.

are wired with all blue

range

Go to Step V.

wires.

62 Code: Fault 56,FMI:3,4)-(SID:26,40,53

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

Go to Step C.

If the resistance is less

Replace the Top 2 valve. Go to

than 10K ohms

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

If voltage is within 1 volt

Top 2 valve is OK, problem exists in

between vehicle

of battery voltage

engine ECM or vehicle harness.

interface harness

Repair according to vehicle OEM

connector pin B and

recommendations. Go to Step V.

ground.

If voltage is outside of

Top 2 valve is functioning properly,

range

problem exists in power supply.

Repair/replace as required. Go to

Step V.

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		If no codes		Test complete.
	(see page 1-8).			If code 62 appears		Return to Step A to find error in
						testing.

62 Code: Fault 56,FMI:3,4)-(SID:26,40,53

2-7

5

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.

1

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)

2																3
4
	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.

3. Measure resistance			If resistance is 14 to 34		Go to Step B.
between Top 2	valve		ohms
connector pins:

•A and B (red & blue wires)

•B and C (blue & white wires)

Note: Some early Top 2 valves

If resistance is outside of

Replace Top 2 valve. Go to Step

are wired with all blue

range

V.

wires.

536 537, Code: Fault

11) FMI: 40,51, (SID:

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

If resistance is 0 to .3

Top 2 valve is functioning properly,

between vehicle

ohms

problem exists in engine ECM or

interface harness

vehicle harness. Repair according

connector pin B and

to OEM recommendations. Go to

ground.

Step V.

If resistance is outside of

Faulty ground. Repair/replace

range

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		If no codes		Test complete.
	(see page 1-8).			If code 537 or 536		Return to Step A to find error in
				appears		testing.

536 537, Code: Fault

11) FMI: 40,51, (SID:

2-11