Fuller Autoshift

8/18/2019 Fuller Autoshift

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Fuller® AutoShift , UltraShift , and

UltraShift PLUS Transmissions

Troubleshooting GuideTRTS0930

November 2009

F-5405B-DM3

F-6405B-DM3

FM-14D310B-LSTFM-15D310B-LST

FO-16D313E-LEP

FO-5406B-DM3

FO-6406A-AW3

FO-6406B-DW3

FO-8406A-AW3

FOM-16D313E-LEP

RTLO-14918A-AS3

RTLO-16913L-DM3

RTLO-16918A-AS3

RTLO-18918A-AS3RTLO-20918A-AS3

RTLO-22918A-AS3

RTLOM-16913L-DM3

RTO-10910B-AS3

RTO-10910B-DM3

More time on the road®

RTO-12910B-AS3

RTO-12910B-DM3

RTO-14910B-AS3RTO-14910B-DM3

RTO-14910C-AS3

RTO-16910B-AS3

RTO-16910B-DM3

RTO-16910C-AS3

RTO-18910B-AS3

RTOM-16910B-DM3

FO-14E310C-LAS

FO-16E310C-LAS

FO-18E310C-LAS

FOM-14E310C-LASFOM-15E310C-LAS

FOM-16E310C-LAS

FM-14E310B-LAS

FM-15E310B-LAS

FO-14E308LL-VCS

FO-16E308LL-VCS

FO-14E309ALL-VMSFO-16E309ALL-VMS

FO-14E313B-MHP

FO-16E313B-MHP

FO-18E313B-MHP

FO-20E313B-MHP

FO-14E318B-MXP

FO-16E318B-MXP

FO-18E318B-MXP

FO-20E318B-MXP

FO-22E318B-MXP

FO-14E318B-VXPFO-16E318B-VXP

FO-18E318B-VXP

FO-20E318B-VXP

FO-22E318B-VXP

®

® ®


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Warnings & Cautions

Warnings & Cautions

Follow the specified procedures in the indicated order to avoid personal injury

Note: Additional relevant information not covered in the service procedure.

Before starting a vehicle:

Ensure adequate fuel level.

• Sit in the driver's seat

• Place shift lever in neutral

• Set the parking brake

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

• Ensure ignition is off while hands are within the clutch housing area.• Place shift lever in neutral


• Block the wheels

When parking the vehicle or leaving the cab:



Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.

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

To avoid damage to the transmission during towing:


• Lift the drive wheels off of the ground or disconnect the driveline

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

WARNING

CAUTION


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Table of Contents

General Information

Warnings & CautionsSuggested Tools ......................................................1-1Transmission Models Included ................................1-3

Diagnostic Procedure ...............................................1-5Fault Code Retrieval/Clearing .................................1-13Fault Code Isolation Procedure Index .....................1-15Symptom-Driven Diagnostics Index .......................1-17Product Diagnostic Mode (PDM) .......... ............... ..1-18

Fault Isolation Procedure

Power-Up Sequence Overview .................................2-1Power Up Sequence Test ............... ............... ........... 2-2Electrical Pretest Overview .....................................2-17

Ignition Circuit Detail ..............................................2-25J-1587 Data Link.....................................................2-26Electrical Pretest .....................................................2-27Component Code: 11 ...... ............... ............... ......... 2-33Component Code: 12 ............. .............. ................. 2-35Component Code: 13 ...... ............... ............... ......... 2-37Component Code: 14 ...... ............... ............... ......... 2-41Component Code: 15 ...... ............... ............... ......... 2-49Component Code: 16 ...... ............... ............... ......... 2-53Component Code 17 ...............................................2-71Component Code: 18 ...... ............... ............... ......... 2-74Component Code: 19 ...... ............... ............... ......... 2-76System Code: 21.....................................................2-80

System Code: 22 ....................................................2-85Component Code: 26 ...... ............... ............... ......... 2-87Component Code 27 ....... ............... ............... ......... 2-92Component Code: 28 ...... ............... ............... ......... 2-98System Code: 29...................................................2-104Component Code 31 ............................................. 2-108Component Code: 32 ............................................ 2-114

Component Code: 33 .......................................... 2-120Component Code: 34 .......................................... 2-126

System Code: 35 ................................................ 2-132System Code: 36 ................................................ 2-140Component Code: 37 ........................................... 2-148System Code: 41 ................................................. 2-156System Code: 42 ................................................ 2-163Component Code: 43 .......................................... 2-170Component Code: 44 .......................................... 2-177System Code: 45 ................................................ 2-181Component Code: 46 .......................................... 2-185Component Code: 51 ........................................... 2-192Component Code: 52 ........................................... 2-198Component Code: 56 .......................................... 2-205Component Code: 57 .......................................... 2-209

Component Code: 58 ........................................... 2-213Component Code: 61. ........................................... 2-219Component Code: 63 ........................................... 2-224System Code: 64 .................................................. 2-229Component Code: 65 ........................................... 2-233Component Code: 66. ........................................... 2-238Component Code: 67 ........................................... 2-241Component Code: 68. ........................................... 2-245Component Code: 71. ........................................... 2-248Component Code: 72. ........................................... 2-257Component Code: 73 ........................................... 2-266System Code: 74 ................................................ 2-275

System Code: 75 ................................................. 2-277Component Code: 81 .......................................... 2-279System Code: 83 ................................................ 2-281System Code: 84 ................................................. 2-283Component Code: 85 ........................................... 2-285Component Code: 99 ........................................... 2-287

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Table of Contents

Symptom Isolation Procedures

Up/Down Button Test Overview ............ ............... ....3-1

Up/Down Button Test ...............................................3-2Start Enable Relay Contact Test Overview ................3-3Start Enable Relay Contact Test ............ ............... ....3-4J-1587 Data Link Test Overview .............................3-13J-1587 Data Link Test ... ............... .............. ............ 3-14Front Box Control Test Overview ............................3-21Front Box Control Test ...........................................3-22AutoShift Will Not Engage a Gear fromNeutral Overview ....................................................3-29AutoShift Will Not Engage a Gear fromNeutral Test ............................................................3-30UltraShift PLUS Will Not Engage a Gear fromNeutral Overview ....................................................3-39

AutoShift Will Not Engage a Gear fromNeutral Test ............................................................3-41UltraShift DM3 Will Not Engage a Gear fromNeutral Overview ....................................................3-52UltraShift DM3 Will Not Engage a Gear fromNeutral Test ............................................................3-53UltraShift AW3 Clutch Engagement Overview ........ 3-64UltraShift AW3 Clutch Engagement Test ................3-65AutoShift AS3 Shift Complaint Overview ................3-68AutoShift AS3 Shift Complaint Test ........................3-69UltraShift PLUS Shift Complaint Overview ............. 3-81UltraShift PLUS Shift Complaint Test .....................3-82UltraShift DM3 Shift Complaint Overview .............. 3-98

UltraShift DM3 Shift Complaint Test ............... ....... 3-99UltraShift AW3 Shift Complaint Overview ............ 3-114UltraShift AW3 Shift Complaint Test ............... ..... 3-115Shift Lever Back Light Overview ...........................3-124Shift Lever Back Light Test .............. ............... ..... 3-125

Appendix

Connector Pin Descriptions ................ ............... .. A-130

UltraShift DM3 6-Speed Wiring Diagram withAnalog Shifter ......................................................A-134UltraShift DM3 6-Speed Wiring Diagram withPush Button Shifter ............................................. A-136UltraShift AW3 6-Speed Wiring Diagram withAnalog Shifter ......................................................A-138UltraShift AW3 6-Speed Wiring Diagram withPush Button Shifter ............................................. A-140AutoShift 10-Speed Wiring Diagram withAnalog Shifter ......................................................A-142AutoShift 10-Speed Wiring Diagram withPush Button Shifter ............................................. A-144UltraShift 10-Speed Wiring Diagram with

Analog Shifter ......................................................A-146UltraShift 10-Speed Wiring Diagram withPush Button Shifter ............................................. A-148UltraShift 13-Speed Wiring Diagram withAnalog Shifter ......................................................A-150UltraShift 13-Speed Wiring Diagram withPush Button Shifter ............................................. A-152AutoShift 18-Speed Wiring Diagram withAnalog Shifter ......................................................A-154AutoShift 18-Speed Wiring Diagram withPush Button Shifter ............................................. A-156UltraShift PLUS Products / Models Wiring Diagramwith Analog Shifter .............................................. A-158

UltraShift PLUS Products / Models Wiring Diagramwith Push Button Shifter .......................... ............ A-160Eaton Shift Lever Wiring Diagram ........................ A-162OEM Shift Lever Wiring Diagram ....................... .. A-163Eaton Push Button Wiring Diagram .... ............... .. A-164OEM J-1939 Shift Input Device Wiring Diagram .. A-165Proper Clutch Operation ................. .............. ....... A-166Adapter Test Kit #J-43318 ................ ............... .... A-168

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1-1

General Information

Suggested Tools

Air Gauges

• 2 (0-100) PSI Air Gauges

Volt/Ohm Meter• SPX / Kent-Moore 1 (800) 328-6657• P/N 5505027

PC-based Service Tool “ServiceRanger”

• Will need version 3.0 for products with UltraShift® PLUS products

• Contact your OEM

Shift Lever Tester• Eaton Service Parts 1 (800) 826-4357

• P/N 691795

Eaton Test Adapter Kit• SPX / Kent-Moore 1 (800) 328-6657• P/N J-43318

6-Pin Deutsch Diagnostic Adapter• SPX / Kent-Moore 1 (800) 328-6657• P/N J-38500-60A

9-Pin Deutsch Diagnostic Adapter• SPX / Kent-Moore 1 (800) 328-6657• P/N J-44012


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1-2

General Information

Vehicle Link Adapters

• RP1210A Compatible USB Adapters recommended for ServiceRanger version 2 and 3

Note: These adapters also support J1708/J1587 and J1939 communications required for SR 3

• Dearborn: DPA 4+Plus

• NEXIQ: USB-Link

• Noregon: JPRO USB-Data Link Adapter

• RP1210A Compatible Adapters for ServiceRanger version 2.x only

• Dearborn Group: DG-DPA-II+

• Caterpillar: CAT Adapter II

• Eaton; MD-100 (RS-232 connection only, not wireless)

• Noregon: JPRO Serial Link Adapter

• NEXIQ: MagiKeyTM Parallel Data Module (PDM) info

Serial (RS-232) to USB Adapters (adapts serial port comm adapters to USB)

• Caterpillar: Model 237-7547

• Belkin: Model EM449AA

• GoldX: Model GXMU-1200

Note: For updated Vehicle Link Adapter information, go to www.roadranger.com, click on "Training." Under the "Training andSupport" heading click on "ServiceRanger." Under the "ServiceRanger" heading click on "Vehicle Link Adapters."

Service Publications

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

TRSM0930 Fuller UltraShift Transmission Service Manual

TRTS0930 Fuller UltraShift Transmission Troubleshooting Guide

TRDR0930 Fuller AutoShift Transmission Driver Instructions

TRDR0940 Fuller UltraShift Transmission Driver Instructions

TRDR1110 Fuller UltraShift PLUS Transmission Driver Instructions


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1-3

General Information

Transmission Models Included

RTO-1X910-AS3 RTO(M)-1X910-DM3

RTLO-1X918-AS3 RTLO(M)-1X913-DM3

F(0)-X406X-AW3 F(0)-X405X-DM3 F(0)-X406X-DM3or


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1-4

General Information

FO-1XE309LL-VMS, FO-1XE308LL-VCS FO-1XE318-VXP or MXP, FO-1XE313-MHP

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


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1-5

General Information

Diagnostic Procedure

Perform procedures and test as directed below for all AutoShift, UltraShift, and UltraShift PLUS product failures.

1. Fill out the Real-Time Warranty Pre-Call Checklist.

2. Using the Automated Driver Questionnaire get a complete and detailed description of the driver’s complaint. Make sureto note the driving conditions when the complaint occurred (hot or cold, wet or dry, all or specific gears.) Also note anychange in the system operation after the complaint occurred.

3. Using an Approved Communication Adapter, connect a PC-based service tool with ServiceRanger software to the vehi-cle diagnostic port.

Note: Only flash codes can be retrieved and cleared using the ignition key if a PC-based service tool with ServiceRanger softwareis not available.

4. Verify the communication adapter is powered. If the adapter does not have a power indicator lamp it may be necessaryto use a volt meter to verify the adapter is getting power from the vehicle’s diagnostic connector.

5. Once the communication adapter is properly connected to the vehicle and the PC, turn the vehicle ignition key to the ON

position and start the ServiceRanger program. Reference the ServiceRanger User Guide for detailed operating informa-tion. (See ServiceRanger version 2 - TCMT0070, ServiceRanger version 3 - TCMT0071.)


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1-6

General Information

6. Retrieve and record the transmission’s current configuration: software levels, transmission model, default and maxi-mum start gear, and shift point configuration.

From the Main Menu,select Product Downloads


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1-7

General Information

7. Retrieve and record complete fault code information: flash code, MID, PID/SID, FMI, count, and time stamp.


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1-8

General Information


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1-9

General Information

8. Turn the vehicle ignition key to the OFF position and allow the transmission to power down for at least two minutes.

9. Confirm neutral is selected on the shift selector.

10. Go to Step A of the Diagnostic Procedure.


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1-10

General Information

Diagnostic Procedure

Step A Procedure Condition Action

1. Key on.

2. Observe gear display.

Note: An "88" mayshow up in thedash at key on. Thisindicates theTransmission ECU hascompleted power-up. Ifthe transmission and geardisplay power-up at thesame time, you may not

see an "88".

If blank Gear Display Go to Step B.

If "-" (Dash) on GearDisplay

Go to Step D.

If “--” (Two Dashes) or"**" (Two Stars) on GearDisplay

Go to Step D.

"#" (Gear Number) onGear Display

a. Verify Shift Lever or PushButton is in Neutral.

b. Turn key off and wait 2minutes.

c. Hold clutch half way to thefloor. (If equipped)

d. Turn on key.

e. If problem continues, call1-800-826-HELP (4357)

"F" (Fault Code) on GearDisplay

Go to Step D.

"N" (Neutral) on GearDisplay

Go to Step B.


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1-11

General Information

Step B Procedure Condition Action

1. Attempt to start engine. No engine crank, lever is inNeutral and Gear Displayis "N" (Neutral)

Perform Start Enable Relay ContactTest.

No engine crank, lever is inNeutral and Gear Display isblank

Perform Power-Up Sequence Test.If no problems found, refer to OEMfor Gear Display problem.

No engine crank and leveris NOT in Neutral




d. Turn on key.

e. If problem continues, call1-800-826-HELP (4357)

Engine cranks and GearDisplay is blank

Refer to OEM for Gear Displayproblem.

Engine cranks and GearDisplay is "N" (Neutral)

Go to Step C.

Step C Procedure Condition Action

1. Engage a gear Unable to engage gear

(ie. flashing gear displaywith down arrows, orsolid "N")

Perform AutoShift Will Not Engage

a Gear from Neutral Test,UltraShift Will Not Engage a Gear

from Neutral Test, UltraShift PLUSProduct Will Not Engage a Gear

From Neutral Test, or UltraShiftAW3 Clutch Engagement Test

depending on transmission type.

Solid "#" (gear number)but no drive

Perform Front Box Control Test.

Gear engaged and drives Go to Step E.


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1-12

General Information

Step D Procedure Condition Action

1. Check for active codes. If codes are present Go to Fault Isolation ProcedureIndex.

If no codes and GearDisplay is "-" (Dash)




d. Turn on key.

e. If problem continues,Perform

See Front Box control Test.

If no codes and GearDisplay is “--” (TwoDashes) or "**" (TwoStars)

Go to Power-Up Sequence Test. Ifno problem found refer to OEM fordisplay problem.

Step E Procedure Condition Action

1. Record and clear inactive faultcodes

2. Drive vehicle

and attemptto reset code.

If no codes are present Test Complete.

If inactive transmissioncomponent or systemcodes

Record codes an call 1-800-826-HELP (4357).

If active transmissioncomponent or systemcodes

Go to Fault Isolation ProcedureIndex.


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1-13

General Information

Fault Code Retrieval/Clearing

Retrieving Fault Codes

Retrieve fault codes by enabling the system’s self-diagnostic mode.

Note: You can also use a PC- based service tool, such as ServiceRanger to retrieve fault codes.

1. Place the shift lever in neutral.

2. Set the parking brake.

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

4. To Retrieve Active Codes: Start with the key in the on position. Turn the key off and on two times within five secondsending with the key in the on position. After five seconds, the service lamp begins flashing two-digit fault codes. If nofaults are active, the service light will flash code 25 (no codes). This is also the procedure to enter Product DiagnosticMode [see page 18]] for details.

Note: An "88" may show up in the dash at key on, which is a normal power-up test of the display.

5. To Retrieve Inactive Codes: Start with the key in the on position. Turn the key off and on four times within five secondsending with the key in the on position. After five seconds, the service lamp begins flashing two-digit fault codes. If nofaults are active, the service light will flash code 25 (no codes).

6. Two digit fault codes will be displayed in the Gear Display. Some vehicle may be equipped with a service light. Observethe sequence of flashes on the service light and record the codes. A one to two second pause separates each storedcode, and the sequence automatically repeats after all codes have been flashed.

2 times

off on

4 times

off on

SERVICE

1 Flash

Shortpause

(1/2 sec)

Short

pause(1/2 sec)

Long Pause(3-4 sec)

3 Flashes 2 Flashes

Code 13 Code 21

SERVICE SERVICE SERVICE SERVICESERVICE

1 Flash

SERVICE


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1-14

General Information

Clearing Fault Codes

The following procedure clears all inactive fault codes from the ECU’s memory. Active fault codes are automatically cleared whenthe fault has been corrected.

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

1. Place the shift lever in neutral.

2. Set the parking brake.

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

4. Start with the key in the on position. Turn the key off and on six times within five seconds ending with the key in the onposition.

Note: If the codes have been successfully cleared, the service lamp will come on and stay on for five seconds. The gear displaywill show 25 (no codes).

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

6 times

off on


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1-15

General Information

Fault Code Isolation Procedure Index

Fault Codes PID SID FMI Description Type of Code

11 254 12 No ECU Operation Component

12 254 13, 14 Improper ECU Configuration Component

13 231 13,12 J-1939 Shift Control Device Component

14 18,19 2, 4, 5 Invalid Shift Lever Voltage Component

15 18 9 HIL Shift Device Communication Component

16 248 2 High Integrity Link (HIL) Component

17 237 3, 4, 14 Start Enable Relay Coil Component

18 34 9 ECA Communication Fault Component

19 248 9 CAN ECA Message Fault Component

21 70 14 Auto Neutral Park Brake Switch System

22 49 9 ABS CAN Message Fault System

25 NO CODES

26 55 10 Clutch Slip Component

27 55 7 Clutch Disengagement Component

28 52,55 3,4,5,7 Clutch System Component

29 372 4, 5 Remote Throttle Enable System

31 218 2,3,4,5,14 Momentary Engine Ignition Interrupt Relay (MEIIR) Component

32 43 2 Loss of Switch Ignition Power Test Component

33 168 4 Low Battery Voltage Supply Component

34 168 14 Weak Battery Voltage Supply Component

35 231 2 J-1939 Communication Link System

36 231 14 J-1939 Engine Message System

37 251 5 Power Supply Component

41 35,36 7 Range Failed to Engage System

42 37,38 7 Splitter Failed to Engage System

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

44 54 3, 4, 5 Inertia Brake Solenoid Coil Component

45 54 7 Intertia Brake Performance System

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

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


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General Information

* This code will only be set inactive

52 59 2, 3, 4, 7 Gear Position Sensor Component

56 161 2, 3, 4, 5,10 Input Shaft Speed Sensor Component

57 160 2, 3, 4, 5 Main Shaft Speed Sensor Component

58 191 2, 3, 4, 5, 6, 8 Output Shaft Speed Sensor Component

61 39 5, 6 Rail Select Motor Component

63 40 5, 6 Gear Select Motor Component

64 34 7, 12 ECA Fault System

65 192 5, 2 ECA Speed Sensor Fault Component

66 34 3, 4 ECA Battery Voltage Fault Component

67 158 3, 4 ECA Ignition Voltage Fault Component

68 227 13, 14 Grade Sensor Fault Component

71 60 7 Unable to Disengage Gear System

72 59 7 Failed to Select Rail System

73 58 7 Failed to Engage Gear System

74 93, 190 7 Engine Failed to Respond System

75* 60 14 Power Down In Gear System

81 47 7 Gear Engagement Detected Component

83 18 14 Shift Lever Missing System

84 18 13 Shift Control Device Not configured System

85 18 12 Shift Control Device Incompatible Component

99 58 14 Direction Mismatch Component

Fault Codes PID SID FMI Description Type of Code


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1-17

General Information

Symptom-Driven Diagnostics Index

Symptom Isolation Procedure

Unable to Shift Transmission with Up/Down Button Up/Down Button Test

Engine Starting System Complaint Start Enable Relay Contact Test

No J1587 Communication J-1587 Data Link Test

Gear Display Shows a Dash Front Box Control Test

AutoShift Will Not Engage a Gear from Neutral AutoShift Will Not Engage a Gear from Neutral Test

UltraShift DM Will Not Engage a Gear from Neutral UltraShift DM Will Not Engage a Gear from Neutral Test

UltraShift AW3 Will Not Engage a Gear from Neutral UltraShift AW3 Clutch Engagement Test

AutoShift AS3 Shift Complaint AutoShift AS3 Shift Complaint Test

UltraShift DM Shift Complaint UltraShift DM Shift Complaint Test

UltraShift AW3 Shift Complaint UltraShift AW3 Shift Complaint Test

Shift Lever Back Light do not work Shift Lever Back Light Test

UltraShift® PLUS Will Not Engage a Gear from Neutral UltraShift® PLUS Will Not Engage a Gear from NeutralTest

UltraShift® PLUS Shift Complaint UltraShift® PLUS Shift Complaint Test


22/479

1-18

General Information

Product Diagnostic Mode (PDM)

Product Diagnostic Mode (PDM) is used to help diagnose inactive codes that may have been set during normal driving. This di-agnostic mode increases the sensitivity of the fault sensing capability

This procedure tests loose, degraded, and intermittent connections. Use the active fault isolation procedure to guide you to thewiring and connectors that are associated with the inactive fault codes. Flex the wiring harness and connectors and attempt torecreate the fault after activating (PDM).

PDM is only to be used by a trained service technician in an authorized dealer.

This procedure is to be used prior to performing fault isolation procedures for component type codes when there are no activecodes present.

To enter PDM mode

Note: Vehicle will not start in Product Diagnostic Mode (PDM). You must turn vehicle key "OFF" and allow the system

to power down to exit PDM.

1. Vehicle must be stationary, engine must not be running, vehicle parking brake must be set.

2. Perform two key clicks of the ignition switch starting in the "ON" position and ending in the "ON" position

Note: An "88" may show up in the dash at key on, which is a normal power-up test of the display.

3. The gear display will flash a 25 then a solid "PD" (Product Diagnostic Mode) and the mode will be activated.

4. The service light shall flash code 25 once indicating no codes. The service light shall then illuminate solid to indicate PDMuntil such time that an active code is detected or PDM is exited.

5. Refer to PDM section in Fault isolation procedure for the inactive fault to be diagnosed.

6. "PD" will remain in gear display until an active fault has been set during the PDM fault isolation procedure.

7. If the fault is detected during PDM mode the gear display will display the active fault/s. The warning tone will only soundwhen the fault is active and the tone will stop when the fault is inactive. The fault will stay in the gear display until thesystem is powered down.

Note: Active codes set during PDM mode will not be stored as inactive.

8. If a fault is detected, exit PDM mode and perform the corresponding "Fault Isolation Procedure".

9. To exit PDM mode, power the system down by turning the key to the "OFF" position.

PDM will only work with the following inactive codes

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


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2-1

Fault Isolation Procedures

Power-Up Sequence Overview

Overview

This test does not relate to any specific fault code, but must

be completed if the self check fails at power up.

Detection

The Transmission ECU checks the program memory everytime the key is turned on.

Fallback

This causes an In Place fallback while moving and a self-check failure if it occurs during power-up.

Required Tools

• Basic Hand Tools

• Troubleshooting Guide

Possible Causes

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

• Vehicle Harness

• Shift Control Device

• Transmission ECU

Top viewof pushbuttonshift control

Side viewof pushbuttonshift control

Pushbutton Shift Control

VOLUMECONTROL

SERVICE

SHIFT

Eaton FullerTransmissions

L

H

D

NR

Transmission controller30-way connector

Eaton Shift Lever


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2-2


Power Up Sequence Test


1. Key off.

2. Remove and clean all battery andbattery to frame connections.

3. Remove and clean ground supplyto engine ECU.

4. Inspect starter/battery and inline30 amp fuse holder connectionsfor corrosion or damagedcontacts.

5. Measure voltage acrossbatteries.

If voltage is 11 to 13 volts ona 12 volt system or 22 to 26on a 24 volt system

Proceed with battery load test.Repair or replace batteries asrequired. Go to Step B.

If voltage is outside of range Repair or replace batteries andcharging system as required.Repeat this step.

30 Amp Fuse

+

–

+

–

+

–

+

–

50 AMP fuse

B C

VOLTS

V COM A

+–

+–


25/479

Power Up Sequence Test, continued

2-3



1. Locate diagnostic port onTransmission Harness.

2. Key on.

3. Measure voltagebetween pins Cand the battery negative post.

If voltage between pin C andthe battery negative post is.70 volts or less

Go to Step C.

If voltage is outside of range Repair battery ground supply toTransmission ECU. Repeat test.

4-Pin Diagnostic Port(Located at the left rear

corner of the t ransmission.)

4-Pin Diagnostics Port

4-way

B - Service Bat. +C - Service Bat. -A - Service Ignition +

VOLTS

V COM A

Battery Negative Post

B A

DC

Warning! - Do Not Load Test at Diagnostic Port


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2-4



1. Locate diagnostic port onTransmission Harness.

2. Key on.

3. Measurevoltage between pins B andpin C.

If voltage between pins B andC is within .6 volts of batteryvoltage

Go to Step D.

If voltage is outside of range Repair battery power supply toTransmission ECU. Fuse may beblown. Repeat test.


4-way


VOLTS

V COM A

B A

DC


corner of the t ransmission.)



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2-5



1. Key on.

2. Measure voltage betweenpin A and pin C.

If voltage between pins A andC is within .6 volts of batteryvoltage

Go to Step E.

If voltage is outside of range Repair Igni tion power supply toECU. Fuse may be blown. Repeattest.


1. Is vehicle equipped withan Shift Lever?

If vehicle is not equippedwith a Shift Lever

Go to Step F.

If vehicle is equipped with aShift Lever

Go to Step K.


4-way


VOLTS

V COM A

B A

DC


corner of the transmission.)



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2-6


Step F Procedure Condition Action

1. Is it an Eaton PushButton or and OEMJ-1939 Shift Device?

If an Eaton Push Button ShiftControl Go to Step G.

If an OEM J-1939 ShiftDevice

Go to Step L.

Step G Procedure Condition Action

1. Key on.

2. Observe service lamp.

Note: If service lampis flashing goto DiagnosticsProcedure(page 2).

If service lamp lights for one

second and turns off

Test complete.

If service lamp never comeson.

Go to Step H.

If service lamp is on steady Replace Shift Control. Go toStep V.

http://-/?-http://-/?-


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2-7


Step H Procedure Condition Action

1. Key off.

2. Disconnect Shift Control 30-wayconnector.

3. Key on.

4. Measure voltage betweenShift Control 30-way pinsC1 and J3.

If voltage is within 1 volt ofbattery voltage

Replace Shift Control. Go toStep V.

If voltage is outside of range Go to Step I.

K

J

H

G

F

E

D

C

B

A

3 2 1

VOLTS

V COM A


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2-8


Step I Procedure Condition Action

1. Key off.

2. Disconnect negative batterycable.

3. Disconnect 38-way VehicleHarness from TransmissionECU.

4. Measure resistance betweenTransmission ECU pin 25 andShift Control connector pin J3and from then from pin J3 toground.

If resistance from pin 25 toJ3 is 0 to .3 ohms andresistance from J3 to groundis 10K or OL

Go to Step J.

If resistance is outside ofrange

Repair the OEM harness. Go to StepV.

K

J

H

G

F

E

D

C

B

A

3 2 1

3 2 1

OHMS

V COM A

28

31

24 25

29 30

15 16

26

20

34

27

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Front View38-Way Connector

K

J

H

G

F

E

D

C

B

A

3 2 1

3 2 1

OHMS

V COM A

Ground


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2-9


Step J Procedure Condition Action

5. Measure resistancebetweenTransmission ECU pin 31and Shift Control connector pinC1and then from pin C1 toground.

If resistance from pin 31to C1 is 0 to .3 ohms andresistance from C1 toground is 10K or OL

Replace the Transmission ECU.Go to Step V.


Repair the OEM harness. Go toStep V.

Step K Procedure Condition Action

1. Is vehicle equippedwith an Eaton supplied ShiftLever or an OEM supplied Shift

Lever.

If Eaton Shift Lever Go to Step M.

If OEM Shift Lever Go to Step S.

K

J

H

G

F

E

D

C

B

A

3 2 1

3 2 1

OHMS

V COM A

28

31

24 25

29 30

15 16

26

20

34

27

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23


K

J

H

G

F

E

D

C

B

A

3 2 1

3 2 1

OHMS

V COM A

Ground


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2-10


Step L Procedure Condition Action

1. Key off.Note: Data link test is designed to test a

signal from an individual ECU. TheECU must be isolated from the restof the Data link.

2. Reconnect engine ECM connector andTransmission ECU 38-way connector.

3. Disconnect the 3-way stub connector,which connects the Transmission ECUinto the J-1939 Data Link.

4. Connect the Data Link Tester to the 3-way stub connector, which connectsthe Transmission ECU into the J-1939Data Link.

Note: If vehicle does not use 3-waystub connectors, then do notreconnect the engine ECMconnector and connect the DataLink Tester across the +/- J-1939terminals (see diagram below).

5. Place the Data Link Tester incommunication test mode.

6. Key on. If LED is solid or flashing Problem exists with theOEM J-1939 Shift Device.Repair according tomanufacturer’srecommendations. Go toStep V.

If LED if off Replace TransmissionECU. Go to Step V.

OFF

COMMUNICATIONTEST

CONTINUITYTESTSELFTEST

OFF

DataLink Tester

PartNo.691582

Transmission ECU

For transmissionDiagnostics perSAE Standard

C

D

B

F

G

A

9-way

AF

J

E

GH

DC

B

J-1939 High

Data Link Tester (Top View)

J-1939 Low


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2-11


Step M Procedure Condition Action

1. Key on.

2. Observe service lamp.

Note: If service lamp isflashing, go toDiagnosticsProcedure(page 2).

If service lamp lights for onesecond and turns off

Test complete.

If service lamp never comeson

Go to Step P.

If service lamp is on steady Go to Step N.

Step N Procedure Condition Action

1. Disconnect Shift Lever 8-wayconnector.

2. Key on.

3. Measure voltage at pin 6

and ground.

If voltage is within 2 volts

of battery voltage for onesecond, then 0 volts

Replace the Eaton Shift Lever.

Go to Step V.

If voltage is constant Go to Step O.

VOLTS

V COM A

1

2

3

4 5

6

7

8

Ground

http://-/?-http://-/?-


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2-12


Step O Procedure Condition Action

1. Key off.

2. Disconnect negative cable.

3. Disconnect 38-way VehicleHarness connector.

4. Measure resistancebetween pin 6 and pin 4.

If resistance between pin 6and 4 is 10K or greater

Replace the Transmission ECU.Go to Step V.

I f resistance is less than 10K Repair the OEM harness. Go toStep V.

Step P Procedure Condition Action1. Key off.


3. Key on.

4. Measure voltage betweenpin 3 and pin 6.

If within 1 volt of battery Replace Eaton Shift Lever. Goto Step V.

If voltage is outside of range Go to Step O.

OHMS

V COM A

1

2

3

4 5

6

7

8

VOLTS

V COM A

1

2

3

4 5

6

7

8


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2-13


Step Q Procedure Condition Action

1. Key off.

2. Disconnect 38-way Vehicle Harnessconnector on Transmission ECU.

Note: On Peterbilt disconnect GearDisplay

3. Measure resistancebetween pin 3 on the 8-wayconnector and pin 25 on the 38-wayconnector and from pin 25 toground.

If resistance between pin 3and 25 is 0 to .3 ohms andresistance from pin 25 to ground is10K ohms or greater

Go to Step R.


Repair harness betweenVehicle Harness 38-wayconnector pin 25 and VehicleHarness 8-way connector pin3. Go to Step V.

OHMS

V C OM A

28

31

24 25

29 30

15 16

26

20

34

27

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

35 10

17

23

Front View

38-Way Connector

OHMS

V COM A

1

2

3

4 5

6

7

8

28

31

24 25

29 30

15 16

26

20

3432 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

27

17

23

Ground

Vehicle Harness 38-way Connector


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2-14


Step R Procedure Condition Action

1. Key off.

2. Measure resistance between:

• Vehicle Harness 38-wayconnector pin 31 andVehicle Harness 8-wayconnector pin 4

• Vehicle Harness 38-wayconnector pin 31 andground

If resistance between pins 31and 4 is 0 to .3 ohms and ifresistance between pin 31 andground is 10K ohms or greater

Replace Transmission ECU. Go toStep V.

If any of the aboveconditions are not met

Repair harness between VehicleHarness 38-way connector pin 31and Vehicle Harness 8-wayconnector pin 4. Go to Step V.

OHMS

V COM A

1

2

3

5

6

7

8

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23


OHMS

V COM A

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground


31

4

31


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2-15


Step S Procedure Condition Action

1. Key off.

2. Locate service lamp connector onOEM harness.

3. Key on.

4. Measure voltage acrosspins A and B on the service lampconnector

If voltage is within 2 volts ofbattery voltage for one second, then0 volts

Test complete.

If no voltage is measured Go to Step T.

If voltage is within 2 volts of

battery voltage continuously

Go to Step U.

Step T Procedure Condition Action

1. Key off.


3. Disconnect 38-way connector

4. Measure resistance frompin A of the OEM connector to pin

23 of the 38-way and from pin 23to ground.

If resistance from pin A to 23is 0 to .3 ohms and resistance to

ground is 10K or greater

Replace the Transmission ECU.

Go to Step V.


Repair the OEM harness. Go toStep V.

Step U Procedure Condition Action

1. Key off


3. Disconnect Transmission ECU38-way connector.

4. Measure voltage across servicelamp connector pins A and B.

If no voltage is measured Replace the Transmission ECU.Go to Step V.

If voltage is within 2 volts ofbattery voltage

Repair OEM harness as required.Go to Step V.


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2-16


Step V Procedure Condition Action

1. Key off.

2. Reconnect all connectors and thenegative battery cable.

3. Key on. If Power-Up Sequence Testcompletes

Test complete.

If Power-Up Sequence Testfails

Return to Step A to find error intesting.


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2-17


Electrical Pretest Overview

Overview

The test does not relate to any specific fault code, but must be

completed before performing Fault Code Isolation table proce-dures. The pretest verifies the batteries are fully charged.

Detection

There is no detection process specifically for the basic electri-cal supply. However, failures of this type are generallydetected by the transmission or driver as some other type offault code or symptom.

Theory of Operation

All Generation 3 products require the OEM to supply power tothe transmission controller (TECU) and to the optional ElectricClutch Actuator (ECA).

Fallback

There is no fallback for the electrical pretest, however, it mayaffect other systems.

Required Tools


• Eaton Test Adapter Kit• Digital Volt/Ohm Meter


• Battery Load Tester

• ServiceRanger a PC-based Service Tool

Possible Causes

The pretest can be used for any of the following:

• Low Batteries

• Starter / Battery connections

• Main power harness to the Transmission ECU


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2-18

Electrical Requirements

Power Harness

Transmission ECU Power Harness

(+) positive side of theMain Battery Source

(-) negative ground sideof the Main Battery Source

Transmission ECU Connector (Vehicle Interface)

J1

OEM responsible forovercurrent protectionon this circuit

30 AMP Fuse

++

Note: Generation 3 is 12-volt or 24-volt compatible


41/479

2-19


Heavy-Duty Electric Clutch Actuator (ECA) Power Harness

(+) positive side of the

Main Battery Source

(-) Ground side of the

Main Battery Source

Note: ECA products are 12-volt only

J1

OEM responsible forovercurrent protectionon this circuit

50 AMP Fuse


42/479

2-20


• The Transmission ECU and ECA must be wired to a non-switched power source at the battery. IF a disconnect switch isrequired, the recommended practice is to wait a minimum of three minutes before using the disconnect switch.

• It is the OEM responsibility to provide power and ground to the Transmission Controller (TECU) and Electric ClutchActuator (ECA) from a reliable battery source from the battery which supplies the starter. The power (+) connection

must include overload protection per Federal Motor Carrier Safety Regulations, Section 393.31. The TECU Main Powerand Ground must be a direct connection from the battery posts to the TECU connector. At 120° C, theseconductors must be able to carry 30 amps @ 9 volts with no more than 0.05 ohms per wire (0.1 ohms total) for a totalvoltage drop from the battery posts to the TECU connector not to exceed 3.0 volts. ECA Main Power and Ground mustbe able to carry 50 amps @ 9 volts with no more than .025 ohms per wire (.05 ohms total) at 120° C. Duration of the50 amp current draw will not exceed 20 milliseconds.

• The Main Power 30 amp fuse connection for the Transmission ECU must be identified with a tag at the battery.

• The Main Power 50 amp fuse connection for the Electric Clutch Actuator (ECA) must be identified with a tag at the bat-tery.

• Battery Positive and Negative must be disconnected PRIOR to any type of welding on any Fuller Automated transmis-sion-equipped vehicles.

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

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

• Battery and Ignition power and ground to the TECU must not be switched off during the engine start process.


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2-21


Preferred +12 Volt Connections

RETR ATS TT AB ERY PLUS 2

RETR ATS ETT AB RY MINUS 2


RETR ATS TT AB ERY PLUS 1+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

RATSOTSREPMUJLAUD-KNABREPSEIRETTABOWT-SKNAB YRETTABOWT TER

REWOP3NEG.SRI APYBLELL AR APNIDETCENNOCER ASEIRETT AB SUPPLIED BY

ASULPHTOB(RETR ATSOTTSESOLCYRETT AB ND MINUS)


RETR ATS TT AB ERY PLUS 1+

-

B A T T E RY

1 2

V OL T

+

-

B A T T E RY

1 2

V OL T

+

-

B A T T E RY

1 2

V OL T

+

-

B A T T E RY

1 2

V OL T

AM G

LER AY

ENNOCSIDHTIWKNABREPSEIRETTABOWT-SKNAB YRETTABOWT CT

EVDN AB ACROFTCENNOCSID-SRI APYBLELL AR APNIDETCENNOCER ASEIRETT AB HICLE START -

P ACTNEMNI ATRETNEDN ATROFMOCB AC"EGR AHCSIDPEED"SEDIVORPRI APDETCENNOCSID ABILITY.

CDN ARETR ATSOTTSESOLCTESYRETT ABMORFDEILPPUSREWOP3NEG OMMON TO CAB POWER

ETT ABUCE3NEG RY MINUS

T ABUCE3NEG TERY PLUS



RETR ATS TT AB ERY PLUS 1

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

IRETTABRUOF-KNAB YRETTABENO ES REWOP3NEG.LELL AR APNIDETCENNOCER ASEIRETT AB SUPPLIED FROM

HTOB(.REWOPB ACHTIWRETR ATSOTTSESOLCYRETT AB PLUS AND MINUS)



TT ABB AC ERY PLUS


TT ABB AC ERY PLUS


44/479

2-22


TIWSTCENNOCSIDEVITAGEN YRETTAB-SKNAB YRETTABOWT CH

EWOP3NEG.EDISNIDEROTSELCIHEVNEHWNWODREWOPT ADETCENNOCSIDER ASEIRETT AB R SUPPLIED FROM BATTERY

DOTNOITCENNOCELB ACELCIHEVFOTNIOPT ANOITCENNOCEVIT AGEN.RETR ATSEHTOTTSESOLC ISCONNECT SWITCH

YRETT AB MINUS

ABRETR ATS TTERY PLUS+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

T ABRETR ATS TERY MINUS

TT ABELCIHEV ERY MINUS



T ABRETR ATS TERY MINUS

ABRETR ATS TTERY PLUS

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

NOITUBIRTSIDREWOP MODULE

TT ABNODETCENNOCSUNIMDN ASULPREWOP,LELL AR APNIDETCENNOCER ASEIRETT AB ERY CLO OTTSES EHT

WOLROFDEZIMITPOHTGNELDN AEZISSELB AC.RETR ATS VOLTAGE DROP



P OWE R

DI S T RI B UT I ON

M OD UL E

( P OWE RB U S A ND

OV E R C URRE NT

DE V I C E S )

STARTER BATTERY MINUS

STARTER

CAB BATTERY PLUS

STARTER BATTERY CONNECTION

GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

Starter Battery PlusGEN 3 ECU BATTERY PLUS

GEN 3 ECU BATTERY MINUS

STARTER BATTERY MINUS 1

STARTER BATTERY PLUS 1

+

-

B A T T E RY

1 2

V OL T

+

-

B A T T E RY

1 2

V OL T

ONE BATTERY BANK - TWO BATTERIES

BATTERIES ARE CONNECTED IN PARALLEL. GEN 3 POWER SUPPLIED FROM

BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS)

GEN 3 ECU BATTERY PLUS

GEN 3 ECU BATTERY MINUS

CAB BATTERY PLUS


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2-23


Preferred +24 Volt Connections

STARTER BATTERY PLUS

2


2


1

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

TWO BATTERY BANKS - TWO BATTERIES IN SERIES PER BANK - DUAL JUMPERS TO

STARTER

BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER

SUPPLIED BY BATTERY CLOSEST TO STARTER (BOTH PLUS AND MINUS)

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

MAG

RELAY

TWO BATTERY BANKS - TWO BATTERIES PER BANK WITH DISCONNECT

BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS - DISCONNECT FOR CAB AND VEHICLE

START - DISCONNECTED PAIR PROVIDES "DEEP DISCHARGE" CAB COMFORT AND ENTERTAINMENT

CAPABILITY. GEN 3 POWER SUPPLIED FROM BATTERY SET CLOSEST TO STARTER AND COMMON TO

CAB POWER

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS


1


1

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

ONE BATTERY BANK - FOUR BATTERIES - ONE CABLE PAIR TO STARTER

BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER

SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS

AND MINUS)

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

CAB BATTERY

PLUS


1


1


1

GEN 3 ECU BATTERY

MINUS

CAB BATTERY

PLUS

GEN 3 ECU BATTERY

PLUS


46/479

2-24


+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

TWO BATTERY BANKS - BATTERY NEGATIVE DISCONNECT SWITCH

BATTERIES ARE DISCONNECTED AT POWER DOWN WHEN VEHICLE STORED INSIDE. GEN 3 POWER SUPPLIED FROM BATTERY

CLOSEST TO THE STARTER. NEGATIVE CONNECTION AT POINT OF VEHICLE CABLE CONNECTION TO DISCONNECT SWITCH

BATTERY

MINUS

STARTER BATTERY

PLUS

STARTER BATTERY

MINUS

VEHICLE BATTERY

MINUS

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

STARTER BATTERY

MINUS

STARTER BATTERY

PLUS

+

-

B A T T E RY

1 2 V OL T

+

-

B A T T E RY

1 2 V OL T

+

-

B A T

T E RY

1 2 V OL T

+

-

B A T

T E RY

1 2 V OL T

POWER DISTRIBUTION MODULE

BATTERIES ARE CONNECTED IN SERIES/PARALLEL, POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE

STARTER. CABLES SIZE AND LENGTH OPTIMIZED FOR LOW VOLTAGE DROP

GEN 3 ECU BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

P OWE R

DI S T RI B UT I ON

M OD UL E

( P OWE RB U S A ND

OV E R C URRE NT

DE V I C E S )

STARTER BATTERY

MINUS

STARTER BATTERY

PLUS

STARTER

CAB BATTERY

PLUS

GEN 3 ECU BATTERY

MINUS

GEN 3 ECU BATTERY

PLUS

STARTER BATTERY CONNECTION

GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.


47/479

2-25


Ignition Circuit Detail

Transmission ECU Ignition Circuit

Note:

Battery and Ignition power and ground to the TECU must not be switched off during the engine start process.

FROM TO

J1-35 VIGN

10 AMP onlyManual resettingcircuit breaker

10 AMPfuseOr

35

23

17

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2

10

6

11 12

4 5

2221

38

36

37

13 14

35

Front ViewTransmission ECU Connector

(Vehicle Interface)

Transmission ECU Connector(Vehicle Interface)

J1Ignition Key Switch

Run to main power lead thatfeeds the ignition bus (OEMresponsible for overcurrent

protection on this line)


48/479

2-26


J-1587 Data Link

Note: A measurement between pin C and D at the diagnostic port should read approximately 60 ohms of resistance (between 50and 70.)

J1939 Troubleshooting

1. Check the resistance of the J-1939 Data Link.

2. With the Key-OFF, measure resistance between the 9-pin diagnostic connector pins C and D and record the reading. Thereading should be 60 ohms of resistance (between 50 and 70.)

3. Check resistance between pins C and A and D and A. These two readings should be 10K ohms or greater (open circuit.)

Note: Pin C = J-1939+, Pin D = J-1939-, Pin A is a chassis ground

4. If an inactive data link fault code is being reported by the Transmission ECU, Product Diagnostic Mode (PDM) should beutilized as outlined in this troubleshooting guide before any further steps are taken.

+ Battery

For TransmissionDiagnostics

J-1587 Data Link

1011

C

D

B

F

G

A

9-way

AF

J

E

GH

DC

B

J1

J-1939 Low

J-1939 High

Transmission ECU Connector

(Vehicle Interface)


49/479

2-27


Electrical Pretest


1. Key off.

2. Remove and clean all battery andbattery to frame connections.

3. Remove and clean ground supplyto engine ECU.

4. Inspect starter/battery and inline30 amp fuse holder connectionsfor corrosion or damaged con-tacts. Also inspect the 50 ampfuse holder on vehicles equippedwith an Electronic Clutch Actua-

tor (ECA).

30 Amp Fuse

+

–

+

–

+

–

+

–

50 AMP fuse

B C


50/479

Electrical Pretest, continued

2-28



5. Measure voltage acrossbatteries. If voltage is 11 to 13 volts ona 12 volt system or 22 to 26on a 24 volt system

Refer to OEM guidelines for bat-tery load test. Repair or replacebatteries as required. Go toStep B.

If voltage is outside of range Repair or replace batteries andcharging system as required.Repeat this step.

VOLTS

V COM A

+–

+–


51/479


2-29



1. Locate diagnostic port on Trans-mission Harness.

2. Key on.

3. Measure voltage betweenpins C and the battery negativepost.

If voltage between pin C andthe battery negative post is.70 volts or less

Go to Step C.

If voltage is outside of range Repair battery ground supply toTransmission ECU. Repeat test.




4-way


VOLTS

V COM A

Battery Negative Post

B A

DC



52/479


2-30



1. Locate diagnostic port on Trans-mission Harness.

2. Key on.

3. Measure voltage betweenpins B and pin C.

If voltage between pins B andC is within .6 volts of batteryvoltage

Go to Step D.

If voltage is outside of range Repair battery power supply toTransmission ECU. Fuse may beblown. Repeat test.


4-way


VOLTS

V COM A

B A

DC





53/479


2-31



1. Key on.

2. Measure voltage betweenpin A and pin C.

If voltage between pins A andC is within .6 volts of batteryvoltage

For non-ECA products, test com-plete. Return to diagnostic pro-cedure. For ECA products, go toStep E.

If voltage is outside of range Repair Igni tion power supply toECU. Fuse may be blown. Repeattest.


4-way


VOLTS

V COM A

B A

DC





54/479


2-32



1. Key off.

2. Disconnect battery negative.

3. Disconnect ECA 3-wayconnector.

4. Reconnect battery negative.

5. Measure voltage between pin Band pin C of 3-way connector.

If voltage between pin B andpin C of 3-way connector iswithin .6 volts of battery volt-age:

Test complete. Return to diag-nostic procedure.

If voltage is outside of range Repair battery power supply toECA. Fuse may be blown. Repeattest.

Transmission ECU

3029

AB

AB

F G

F G

50 AMP fuse

Battery power(Non-switched power)

run to starter or Battery

Engine Flywheel Speed Sensor

B C

ABC

13


55/479

2-33


Component Code: 11(SID 254, FMI 12)No ECU Operation

Overview

This fault code indicates an internal failure of the Transmis-sion ECU.

Detection

The Transmission ECU checks the program memory everytime the key is turned on and throughout operation. If theTransmission ECU is able to detect a failure within its ownmemory, it sets this fault code.

Fallback

This fault causes a vehicle In Place fallback while moving anda self-check failure if it occurs during power-up.

Required Tools• Troubleshooting Guide


Possible Causes

This fault code can be caused by the following:


Transmission ECU


56/479

2-34


Code 11 (SID 254, FMI 12), No ECU Operation Test


1. Key on.

2. Retrieve Codes (seepage 1-13).

If code 11 is active Replace Transmission ECU.

If code 11 is inactive Test complete.


57/479

2-35


Component Code: 12(SID 254, FMI 13, 14)Improper ECU Configuration

Overview

This fault code indicates the ECU is not reading valid informa-tion from memory, including the transmission table and cali-bration values.

Detection

The Transmission ECU checks the Configuration every timethe key is turned on. If the transmission is not able to detectthe proper Configuration, it sets this fault code.

Fallback

This fault causes a power up no crank.

Required Tools• Troubleshooting Guide


Possible Causes


• Improper ECU Configuration Software

Transmission ECU


58/479

2-36


Code 12 (SID 254, FMI 13, 14), Improper ECU Configuration Test


1. Key on.

2. Retrieve codes (seepage 1-13).

If code 12 is active Customer - Call Eaton at 1-800-826-HELP (4357). CSC - CallTechnician Service.

If code 12 is inactive Test complete.


59/479

2-37


Component Code: 13(SID 231, FMI 12, 13)J-1939 Shift Control Device

Overview

This fault indicates communication has been lost, or does notcorrespond with the neutral request input from the J-1939Shift Device.

When troubleshooting an Inactive code See “Product Diag-nostic Mode (PDM)” on page 18.

Detection

Starting at key on and throughout operation, the Transmis-sion ECU constantly monitors communication with the J-1939

Shift Device. If a neutral request from the J-1939 Shift Devicedoes not match the neutral signal or is not received from theJ-1939 Shift Device, fault code 13 is set.

Fallback

This fault causes a downshift only fallback. Once the trans-mission re-engages the start gear, there will be no upshifts aslong as the code is active.

Required Tools• ServiceRanger a PC-based Service Tool


• Eaton Test Adapter Kit

• Digital Volt/Ohm Meter


Possible Causes


• OEM J-1939 Shift Control Device

• Vehicle Harness

J1

OEM J-1939 Shift Device

Bulkhead connectorlocated at firewall

J-1939

Transmission ECU Connector(Vehicle Interface)

1617

Switched Power

GroundBattery Power (Non-switched powerrun to Battery or Starter)


60/479

2-38


Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Test


1. Key off.

2. Disconnect negative battery ca-ble.

3. Disconnect Vehicle Harness 38-way connector.

4. Measure resistance be-tween 38-way connectorpin 16 and correspond-ing OEM pin at J-1939Shift Device and pin 16and ground (see OEM

wiring for correct pin location)

If resistance is 0 to .3 ohmsbetween pin 16 and the cor-responding OEM pin and re-sistance to ground is 10Kohms or greater

Go to Step B.

If resistance is out of range Repair wiring between Trans-mission ECU and J-1939 ShiftDevice. Go to Step V.

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

35 10

17

23



OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground

OHMS

V COM A

To OEM J-1939Shift Device Pin


61/479

Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Fault Test, continued

2-39



1. Measure resistance be-tween 38-way connectorpin 17 and correspondingOEM pin at J-1939 ShiftDevice and pin 17 andground (see OEM wiringfor correct pin location)

If resistance is 0 to .3 ohmsbetween pin 17 and the cor-responding OEM pin and re-sistance to ground is 10Kohms or greater

Problem exists with the J-1939Shift Device, or J-1939 Shift De-vice power, ground or datalinkwiring. Contact your OEM for re-pair strategy. Go to Step V.

If resistance is out of range Repair wiring between Trans-mission ECU and J-1939 ShiftDevice. Go to Step V.

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23



OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground

OHMS

V COM A

To OEM J-1939Shift Device Pin


62/479

Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Fault Test, continued

2-40



1. Key off.


3. Key on.

4. Clear codes (see page 1-13).

5. Drive vehicle and attempt to resetthe code.

6. Check for codes (seepage 1-13).

If no codes Test complete.

If code 13 appears Return to Step A to find error intesting.

If code other than 13 ap-pears

Go to Fault Code Isolation Pro-cedure Index (see page 1-15).


63/479

2-41


Component Code: 14(SID 18, 19, FMI 2, 4, 5)Invalid Shift Lever Voltage

Overview

This fault code indicates an electrical failure of the Eaton ShiftLever or OEM Shift Lever.

When troubleshooting an Inactive code See “Product Diag-nostic Mode (PDM)” on page 18.

Detection

Starting at key-on and throughout operation, the Transmis-sion ECU constantly measures the feedback from the ShiftLever circuit. If the feedback is out of range, the fault is set.

This type of failure represents a short to battery, short toground, or open circuit.

Fallback

This fault may cause a downshift only fallback mode. Once thetransmission re-engages the start gear, there will be noupshifts as long as the code is active.

Required Tools• Basic Hand Tools


• Shift Stalk Tester




Possible Causes

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

• Eaton Shift Lever or OEM Shift Lever

• OEM Harness


Transmission ECUEaton Shift Lever


64/479

2-42


Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test


1. Is vehicle equipped withan Eaton supplied Shift Lever oran OEM supplied Shift Lever?

If Eaton Shift Lever Go to Step B.

If OEM Shift Lever Contact OEM for troubleshootingprocedures.


1. Key off.


3. Connect Shift Lever tester to the8-way Shift Lever harness.

4. Connect ServiceRanger a PC-based Service Tool to diagnosticport.

5. Key on.

6. Select Monitor Data.

7. Observe transmissionrange selected.

If transmission rangeselected equals neutral

Replace Shift Lever (Only ifFault Code is Active). Go toStep V.

If transmission rangeselected does not equal neutral

Go to Step C.


65/479

Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test, continued

2-43



1. Key off.


3. Disconnect Transmission ECU38-way connector.

4. Remove tester from ShiftLever 8-way connector.

5. Measure resistancebetween:

• ECU 38-way

pin 15 andShift Lever 8-way connector pin 1

• ECU 38-way connectorpin 15 and ground

If resistance between pins 15and 1 is 0 to .3 ohms andresistance between pin 15

and ground is 10K ohms orgreater

Go to Step D.


Repair Vehicle Harness between theTransmission ECU and the ShiftLever. Go to Step V.

OHMS

V COM A

1

2

3

4 5

6

7

831

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23


OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground



66/479


2-44



1. Key off.


• ECU 38-waypin 16 andShift Lever 8-way connector pin 8

• ECU 38-way connector pin16 and ground

If resistance between pins 16and 8 is 0 to .3 ohms andresistance between pin 16and ground is 10K ohms orgreater

Go to Step E.


Repair Vehicle Harness betweenthe Shift Lever and TransmissionECU. Go to Step V.

OHMS

V COM A

1

2

3

4 5

6

7

8

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23


OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground



67/479


2-45



1. Key off.


• ECU 38-way pin 17 andShift Lever 8-way connectorpin 2

• ECU 38-way connector pin17 and ground

If resistance between pins 17and 2 is 0 to .3 ohms andresistance between pin 17and ground is 10K ohms orgreater

Go to Step F.


Repair Vehicle Harness betweenShift Lever and TransmissionECU. Go to Step V.

OHMS

V COM A

1

2

3

4 5

6

7

8

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23


OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

Ground



68/479


2-46


Step F Procedure Condition Action

1. Key off.


• Transmission ECU 38-wayconnector pin 15 and 16and 15 and 17. Thenmeasure resistance frompin 16 to 17.

If resistance on all three is10K ohms or greater

Replace Shift Lever. Go to StepV.

If any of the three readings isless than 10K ohms

Repair Vehicle Harness betweenShift Lever and TransmissionECU. Go to Step V.

OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23

OHMS

V COM A

31

24 25

29 30

15 16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

17

23



OHMS

V COM A

31

24 25

29 30

16

26

20

34

27 28

32 33

18 19

7

3

8 9

1 2 6

11 12

4 5

2221

38

36

37

13 14

3510

15

23

17


69/479


2-47



1. Key off.


3. Key on.

4. Clear codes (see page 1-13).

5. Drive vehicle and attempt to resetthe code.

6. Check for codes (seepage 1-13).

If no codes Test complete.

If code 14 appears Return to Step A to find error intesting.

If code other than 14appears

Go to Fault Code IsolationProcedure Index (see page 1-15).


70/479


2-48



71/479

2-49


Component Code: 15(SID 18, FMI 9)HIL Shift Device Communication

Overview

Controller Area Network (CAN) is a high-speed twisted pair500K proprietary datalink with one 120 ohm resistor at eachend of the link. The Transmission ECU is connected to theCAN datalink at the 38-way connector. This link is used totransmit information to the ECU as well as communicate orreceive data from the other modules on the network like theHIL Shift Device. See "Product Diagnostic Mode (PDM)" sec-tion for more information on troubleshooting inactive codes.

Detection

Fault Code 15 is set when the ECU fails to receive Shift Devicedata for 5 continuous seconds, and it is still communicatingwith other modules on CAN.

Fallback

This fault causes a downshift only fallback while moving.Once the transmission re-engages the start gear, there will beno upshifts as long as the code is active. If the code is activeduring power-up a flashing "F" will appear on the gear displayand the Transmission ECU will not engage a gear.

Required Tools• Basic Hand Tools




• ServiceRanger, PC-based service tool

Possible Causes

• CAN data link

• HIL Shift Device


72/479

2-50


PNL CAN TERMINATINGRESISTOR

(INTERNAL TO GEN 3 ECM)

PNL CAN TERMINATING

RESISTOR(INTERNAL TO PNL SHIFT CONSOLE)

PNL CAN LOW (TRANSMISSION)

PNL CAN LOW (VEHICLE)

PNL CAN HIGH (TRANSMISSION)

PNL CAN HIGH (VEHICLE)

TERMINAT

Documents

Fuller Autoshift