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
• Set the parking brake
• Block the wheels
When parking the vehicle or leaving the cab:
• Place shift lever in neutral
• Set the parking brake
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:
• Place shift lever in neutral
• 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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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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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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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
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)
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)
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,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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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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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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1-16
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
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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
Fault Isolation Procedures
Power Up Sequence Test
Step A Procedure Condition Action
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
+–
+–
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Power Up Sequence Test, continued
2-3
Fault Isolation Procedures
Step B Procedure Condition Action
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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Power Up Sequence Test, continued
2-4
Fault Isolation Procedures
Step C Procedure Condition Action
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-Pin Diagnostics Port
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
VOLTS
V COM A
B A
DC
4-Pin Diagnostic Port(Located at the left rear
corner of the t ransmission.)
Warning! - Do Not Load Test at Diagnostic Port
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Power Up Sequence Test, continued
2-5
Fault Isolation Procedures
Step D Procedure Condition Action
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.
Step E Procedure Condition Action
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-Pin Diagnostics Port
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
VOLTS
V COM A
B A
DC
4-Pin Diagnostic Port(Located at the left rear
corner of the transmission.)
Warning! - Do Not Load Test at Diagnostic Port
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Power Up Sequence Test, continued
2-6
Fault Isolation Procedures
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.
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Power Up Sequence Test, continued
2-7
Fault Isolation Procedures
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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Power Up Sequence Test, continued
2-8
Fault Isolation Procedures
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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Power Up Sequence Test, continued
2-9
Fault Isolation Procedures
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.
If resistance is outside ofrange
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
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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Power Up Sequence Test, continued
2-10
Fault Isolation Procedures
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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Power Up Sequence Test, continued
2-11
Fault Isolation Procedures
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
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Power Up Sequence Test, continued
2-12
Fault Isolation Procedures
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.
2. Disconnect Shift Lever 8-wayconnector.
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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Power Up Sequence Test, continued
2-13
Fault Isolation Procedures
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.
If resistance is outside ofrange
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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Power Up Sequence Test, continued
2-14
Fault Isolation Procedures
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
Front View38-Way Connector
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
Vehicle Harness 38-way Connector
31
4
31
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Power Up Sequence Test, continued
2-15
Fault Isolation Procedures
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.
2. Disconnect negative batterycable.
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.
If resistance is outside ofrange
Repair the OEM harness. Go toStep V.
Step U Procedure Condition Action
1. Key off
2. Disconnect negative batterycable.
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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Power Up Sequence Test, continued
2-16
Fault Isolation Procedures
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
Fault Isolation Procedures
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
• Basic Hand Tools
• Eaton Test Adapter Kit• Digital Volt/Ohm Meter
• Troubleshooting Guide
• 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
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2-19
Electrical Requirements
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
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2-20
Electrical Requirements
• 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
Electrical Requirements
Preferred +12 Volt Connections
RETR ATS TT AB ERY PLUS 2
RETR ATS ETT AB RY MINUS 2
RETR ATS ETT AB RY MINUS 1
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 ETT AB RY MINUS 1
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
ETT ABUCE3NEG RY MINUS
RETR ATS ETT AB RY MINUS 1
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)
T ABUCE3NEG TERY PLUS
ETT ABUCE3NEG RY MINUS
TT ABB AC ERY PLUS
T ABUCE3NEG TERY PLUS
TT ABB AC ERY PLUS
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2-22
Electrical Requirements
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 ABUCE3NEG TERY PLUS
ETT ABUCE3NEG RY 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
T ABUCE3NEG TERY PLUS
ETT ABUCE3NEG RY 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
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
Electrical Requirements
Preferred +24 Volt Connections
STARTER BATTERY PLUS
2
STARTER BATTERY MINUS
2
STARTER BATTERY MINUS
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
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
+
-
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
STARTER BATTERY PLUS
1
STARTER BATTERY MINUS
1
STARTER BATTERY PLUS
1
GEN 3 ECU BATTERY
MINUS
CAB BATTERY
PLUS
GEN 3 ECU BATTERY
PLUS
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2-24
Electrical Requirements
+
-
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.
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2-25
Electrical Requirements
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)
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2-26
Electrical Requirements
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)
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2-27
Fault Isolation Procedures
Electrical Pretest
Step A Procedure Condition Action
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
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Electrical Pretest, continued
2-28
Fault Isolation Procedures
Step A Procedure Condition Action
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
+–
+–
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Electrical Pretest, continued
2-29
Fault Isolation Procedures
Step B Procedure Condition Action
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-Pin Diagnostic Port(Located at the left rear
corner of the transmission.)
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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Electrical Pretest, continued
2-30
Fault Isolation Procedures
Step C Procedure Condition Action
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-Pin Diagnostics Port
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
VOLTS
V COM A
B A
DC
4-Pin Diagnostic Port(Located at the left rear
corner of the transmission.)
Warning! - Do Not Load Test at Diagnostic Port
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Electrical Pretest, continued
2-31
Fault Isolation Procedures
Step D Procedure Condition Action
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-Pin Diagnostics Port
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
VOLTS
V COM A
B A
DC
4-Pin Diagnostic Port(Located at the left rear
corner of the transmission.)
Warning! - Do Not Load Test at Diagnostic Port
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Electrical Pretest, continued
2-32
Fault Isolation Procedures
Step E Procedure Condition Action
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
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2-33
Fault Isolation Procedures
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
• ServiceRanger a PC-based Service Tool
Possible Causes
This fault code can be caused by the following:
• Transmission ECU
Transmission ECU
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2-34
Fault Isolation Procedures
Code 11 (SID 254, FMI 12), No ECU Operation Test
Step A Procedure Condition Action
1. Key on.
2. Retrieve Codes (seepage 1-13).
If code 11 is active Replace Transmission ECU.
If code 11 is inactive Test complete.
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2-35
Fault Isolation Procedures
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
• ServiceRanger a PC-based Service Tool
Possible Causes
This fault code can be caused by the following:
• Improper ECU Configuration Software
Transmission ECU
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2-36
Fault Isolation Procedures
Code 12 (SID 254, FMI 13, 14), Improper ECU Configuration Test
Step A Procedure Condition Action
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.
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2-37
Fault Isolation Procedures
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
• Basic Hand Tools
• Eaton Test Adapter Kit
• Digital Volt/Ohm Meter
• Troubleshooting Guide
Possible Causes
This fault code can be caused by the following:
• 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)
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2-38
Fault Isolation Procedures
Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Test
Step A Procedure Condition Action
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
Front View38-Way Connector
Vehicle Harness 38-way Connector
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
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Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Fault Test, continued
2-39
Fault Isolation Procedures
Step B Procedure Condition Action
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
Front View38-Way Connector
Vehicle Harness 38-way Connector
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
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Code 13 (SID 231, FMI 12, 13), J-1939 Shift Control Device Fault Test, continued
2-40
Fault Isolation Procedures
Step V Procedure Condition Action
1. Key off.
2. Reconnect all connectors and thenegative battery cable.
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).
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2-41
Fault Isolation Procedures
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
• Eaton Test Adapter Kit
• Shift Stalk Tester
• Troubleshooting Guide
• ServiceRanger a PC-based Service Tool
• Digital Volt/Ohm Meter
Possible Causes
This fault code can be caused by any of the following:
• Eaton Shift Lever or OEM Shift Lever
• OEM Harness
• Transmission ECU
Transmission ECUEaton Shift Lever
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2-42
Fault Isolation Procedures
Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test
Step A Procedure Condition Action
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.
Step B Procedure Condition Action
1. Key off.
2. Disconnect Shift Lever 8-wayconnector.
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.
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Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test, continued
2-43
Fault Isolation Procedures
Step C Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
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.
If any of the aboveconditions are not met
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
Front View38-Way Connector
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
Vehicle Harness 38-way Connector
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Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test, continued
2-44
Fault Isolation Procedures
Step D Procedure Condition Action
1. Key off.
2. Measure resistancebetween:
• 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.
If any of the aboveconditions are not met
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
Front View38-Way Connector
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
Vehicle Harness 38-way Connector
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Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test, continued
2-45
Fault Isolation Procedures
Step E Procedure Condition Action
1. Key off.
2. Measure resistancebetween:
• 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.
If any of the aboveconditions are not met
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
Front View38-Way Connector
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
Vehicle Harness 38-way Connector
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Code 14 (SID 18, 19 FMI 2, 4, 5), Invalid Shift Lever Voltage Test, continued
2-46
Fault Isolation Procedures
Step F Procedure Condition Action
1. Key off.
2. Measure resistancebetween:
• 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
Front View38-Way Connector
Vehicle Harness 38-way Connector
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
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Fault Isolation Procedures
Step V Procedure Condition Action
1. Key off.
2. Reconnect all connectors and thenegative battery cable.
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).
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Fault Isolation Procedures
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Fault Isolation Procedures
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
• Eaton Test Adapter Kit
• Digital Volt/Ohm Meter
• Troubleshooting Guide
• ServiceRanger, PC-based service tool
Possible Causes
• CAN data link
• HIL Shift Device
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Fault Isolation Procedures
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