Eaton TRTS4400 Bedienungsanleitung

Fuller® Transmission

Troubleshooting Guide

TRTS4400

September 2009

FTS-XX108LL

FTS-XX112L

Table of Contents

General Information

Warnings and Cautions ............................................................................................................................................. 1

Suggested Tools ....................................................................................................................................................... 2

Electro Pneumatic Diagnose Tools............................................................................................................................. 2

Transmission Models Included ................................................................................................................................. 3

Diagnostic Procedure

Symptom Based Isolation Procedure / Technique ..................................................................................................... 4

Fault Status Retrieval / Clearing ................................................................................................................................ 4

Symptom Based Driving Procedure .......................................................................................................................... 5

Symptom Overview .................................................................................................................................................... 6

Vehicle Electrical Pretest ........................................................................................................................................... 7

Pneumatic Pretest ...................................................................................................................................................... 8

Symptom Based Diagnostic Tests.............................................................................................................................. 9

System Not Able to Default to Low Range with Flashing Service Lamp ..................................................................... 10

Service Lamp Does Not Turn on During Power Up ................................................................................................... 11

Component Test Procedures

FTS-XX108LL Symptom Diagnostic Table ................................................................................................................ 12

FTX-XX112L Symptom Diagnostic Table .................................................................................................................. 18

Component Based Diagnostic Procedures ................................................................................................................ 23

Appendix

Connector Pin Descriptions ....................................................................................................................................... 28

Wiring Diagrams for All Models ................................................................................................................................ 29

Air System Overview .................................................................................................................................................. 31

Master Control Valve Configurations.......................................................................................................................... 37

Eaton Test Tool (Breakout Box) ................................................................................................................................. 38

Electrical Harness Diagram ....................................................................................................................................... 39

Component Locations ............................................................................................................................................... 39

Multimeter Specifications........................................................................................................................................... 42

Warnings & Cautions

General Information

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.

Unplug the TCM before electrical welding service in any part of the vehicle.

All electrical connectors require maximum care when plugging or unplugging them from the TCM, harness, and compo-

nents.

WARNING

CAUTION

General Information

Suggested Tools

• Eaton Breakout Box Test Tool

• Breakout Box - E015002

• Harness - E015001

• Multimeter able to measure frequency (see appendix for specifications)

• Manometer (0 -10 bar)

• Service Publications

• S-13 Transmission Service Manual, TRSM4400

• S10 Transmission Service Manual, TRSM4300

• Bypass System Troubleshooting Guide, TRTS4400

• Driver Instructions for FTS/FTSO-XX1108LL, TRDR4300

• Driver Instructions for FTS/FTSO-XX112L, TRDR4400

Note: For more information call Eaton Support 0800 17 05 51 (Valid only in Brazil)

Electro Pneumatic Diagnose Tools

Breakout Box and Harness

General Information

Transmission Models Included

FTS-XX108LL

FTS-XX112L

Diagnostic Procedure

Symptom Based Isolation Procedure / Techniques

Fault Status Retrieval / Clearing

Fault Status Retrieval

• Retrieve Fault status by observing the transmission service lamp

1. Place 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 can still retrieve fault sta-

tus.

4. To observe fault status locate the transmission service lamp on the vehicle dash area; if the service lamp is flashing

consistently (more than 2 flashes) the transmission system has an active fault.

Note: The service lamp merely indicates that there is a fault in the transmission system by flashing consistently; diagnostic pro-

cess will indicate which component/sub-system has failed.

Note: Under normal conditions at key on the service lamp will flash 2 times indicating that the transmission system is powered

up and functioning properly.

Clearing Faults

• Any component or sub-system fault will clear itself when the transmission system powers up if a successful repair of

the previous detected fault has been completed.

Diagnostic Procedure

Symptom-Based Driving Procedure

If Driver Feedback is Available

1. Verify complaint with driver

2. Operate vehicle according to driver specified operation conditions

3. Reproduce symptom

4. Record symptom specifics such as speeds, conditions, and service lamp status

5. If service lamp is not flashing and a symptom is still present refer to specific model service manual for general trouble-

shooting symptoms and procedures

6. For additional assistance if symptom still present after all troubleshooting procedures have been attempted please con-

tact Eaton Support at 0800 170551

If Driver Feedback is Not Available

1. Operate vehicle to normal operating temperatures

2. Operate vehicle in which several range shifts are attempted in each range selection

3. Reproduce symptom

4. Record symptom specifics such as speeds, conditions, and service lamp status

5. If service lamp is not flashing and a symptom is still present refer to specific model service manual for general trouble-

shooting symptoms and procedures

6. For additional assistance if symptom still present after all troubleshooting procedures have been attempted please con-

tact Eaton Support at 0800 170551

Diagnostic Procedure

Sympton Overview

High-Speed Downshift Protection

The Orion control module is equipped with advanced diagnostic features to evaluate the integrity of the system and provide oper-

ator feedback of a system fault. In addition, if the fault shall result in a condition that shall compromise the reliability of the trans-

mission or result in a safety risk, the system logic will compensate and default to a safe mode. The diagnostic capability of the

control module includes identification of the following component failures. The service light used for identification of a compo-

nent failure is on for 2 seconds upon vehicle start up to allow for identification of a service light burn-out. The service light will

flash for 1 second on and 1 second off for the following failures:

• Speed Sensor Failure

• Range Valve Failure

• Deep Range Valve Failure

• Range Switch Failure

• Deep Range Switch Failure

• Pneumatic Failure (a pneumatic failure resulting in the engagement of the 4th and not-allowed deep range state will

result in a high range default and fault identification

• Ignition Failure (the control module will not shut off if the ignition fails while the vehicle is moving).

• Battery Failure (the control module is capable of operating on the ignition power if the battery shall fail while the vehicle

is moving).

Prevent Deep / High Selection

The transmission utilizes two range pistons, each with a for/aft position to achieve three range positions. The mechanical design

of the actuation and engagement system results in a total of four potential configurations. The fourth position that is not utilized

results in an auxiliary ratio of deep range. However, while the transmission power flow achieves the deep ratio, the load and dif-

ferential speed imparted on the mechanical elements can result in damage to the transmission. To prevent transmission damage

and operator confusion, the system is designed to prevent this configuration. This is prevented by a mechanical interlock in the

master control valve that prevents selection of this configuration. However, analysis has indicated that there are electrical and

pneumatic failure modes that can result in this configuration. The control module is equipped with logic to recognize this and

automatically shift the transmission to high range.

Bypass System

If the transmission has a electronic component failure it will go into down shift protection mode. When in down shift protection,

the transmission will engage high range at the first opportunity and will keep it in high range until the source of the failure is

gone. The by-pass mode was created to allow the vehicle to be driven only in low range if high range is not suitable for condi-

tions. This will allow the vehicle to be driven to a place where the repair can be done. To turn on the by-pass system the driver

must stop the vehicle, use the parking brake and turn on the by-pass OEM control (inside the vehicle cabin).

Diagnostic Procedure

Vehicle Electrical Pretest

Step A

•KeyOff

• Remove chassis interface connector (J1) from transmission control module and use a Volt Ohm-Meter to measure

resistance between Battery (-) Negative pins 7 and 8 and Negative Battery Post.

• If battery (-) negative pin 7 and 8 reading is between 0 and 1 ohms, continue to Step B.

• If the reading is outside of range, repair ground supply according to OEM guidelines. Repeat Step A to verify

ground supply.

Step B

•KeyOn

• From the (J1) connector use a Volt Ohm-Meter to measure voltage between Vehicle Ignition pin 6 and Battery (-) Nega-

tive pins 7 and 8.

• If voltage is between 11 and 13 volts on a 12-volt system, or 22 to 26 on a 24-volt system, continue to Step C.

• If voltage is outside of range, repair Vehicle Ignition voltage supply according to OEM guidelines. Repeat Step B to

verify Ignition voltage supply.

Step C

•KeyOn

• From the (J1) connector use a Volt Ohm-Meter to measure voltage battery between Battery Positive pin 5 and Battery

(-) Negative pins 7 and 8.

• If voltage is between 11 and 13 volts on a 12-volt system, or 22 and 26 volts on a 24-volt system, test complete.

• If voltage is outside of range, repair Battery Positive voltage supply according to OEM guidelines. Repeat Step C to

verify Battery Positive voltage.

Diagnostic Procedure

Pneumatic Pretest

Step A

• Ignition Off

• Using a 4-bar minimum pressure gauge, check chassis air pressure going into air / filter regulator.

• If reading is 8-9 bar, continue to Step B.

• If the reading is outside of range, repair air pressure according to OEM guidelines. Repeat Step A.

Step B

• Using a 4-bar minimum pressure gauge, check pressure on transmission output side of air / filter regulator.

• If reading is 7.34 - 7.93 bar continue to symptom based diagnostic isolation procedures section.

• If reading is outside of range, replace air filter regulator and repeat Step B to verify air pressure reading.

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