Eaton TRTS4400, Troubleshooting Manual

Page 1: ...Fuller Transmission Troubleshooting Guide TRTS4400 September 2009 FTS XX108LL FTS XX112L ...

Page 2: ... 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 Overvie...

Page 3: ...ls 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 whee...

Page 4: ...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 ...

Page 5: ...3 General Information General Information Transmission Models Included FTS XX108LL FTS XX112L ...

Page 6: ...icle 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 ...

Page 7: ...om 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 servic...

Page 8: ...n 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 ...

Page 9: ...ure 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 Key On From the J1 connector use a Volt Ohm Meter to measure...

Page 10: ...e 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 re...

Page 11: ...liary section of Service Manual First Step Procedure 1 Checking the Condition of the System 1 Overall system review checking for loose or damaged wires or connectors 2 Turn off the vehicle and keep the key in the OFF position 3 Check if the bypass OEM control is turned off inside the vehicle Location of OEM bypass control will vary Please con tact OEM for location 4 Unplug the negative plug from b...

Page 12: ...r removing the airline actuate the OEM supplied control that allows the driver to switch default from high to low range and check for airflow If air is present proceed to the Range Solenoid Valve Test in the Component Test Procedures Section If no air is present contact the OEM for troubleshooting procedures Note For the FTS XX112L model transmissions the bypass valves are hooked together in serie...

Page 13: ...x blinks check the vehicle service lamp and its connection harness 4 If only the vehicle service lamp blinks check the breakout box and the harness 5 If none of the lamps blinks replace the TCM Procedure 2 1 Unplug the negative plug from battery 2 Turn off the vehicle keep the key on position OFF 3 Unplug the connector P1 and J1 from TCM 4 Plug P1 and J1 on P1B and J1B 5 Plug P1A and J1A on ECU 6 ...

Page 14: ...orm all tests with the lever in Neutral position SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Low range doesn t work Pilot air line Remove the air line P at range valve Select low range at the knob There is air supply None There isn t air sup ply Check if there is air leakage through P air line Check if the knob is supplying air to air line P If not replace the knob Remove the air line P at range val...

Page 15: ...supply is correctly assem bled Check the hoses if they are ok and there is no air flow replace the master control valve SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Deep range doesn t work Pilot air line Remove the air line SP at range valve Select deep range at the knob There is air supply None There isn t air sup ply Check if there is air leakage through SP air line Check if the knob is supplying a...

Page 16: ... supply is correctly assem bled Check the hoses if they are ok and there is no air flow replace the master control valve SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Shifting low range low low is slow or doesn t work Air filter regulator Assemble the manometer in the output at the air fil ter Measure the output pres sure 7 3 bar 7 56 bar is the work pres sure Assemble the manometer at the air filter ...

Page 17: ...gh range work cor rectly Replace the range valve If low and high range doesn t work correctly Check the transmission next item Insert valve Emboloplunger Remove the air supply SP low low see picture in the end of this section and select low low at the knob be sure to fas ten the hose to avoid acci dents There is air supply None Go to next step There isn t air sup ply Check if the air supply is cor...

Page 18: ...stem doesn t work Low performance between 6 0 e 7 0 bar Higher than de 7 0 bar normal Obs2 If any solid contamination is found replace the air filter regulator Obs3 Pictures of Exhaust Valve assembly Correct Pin and Spring Assembling at Exhaust Valve Low and High Range Air Input ...

Page 19: ...17 Component Test Procedures Component Test Procedures Low Low On and Off Air Input Low and High Range and Low Low Air Input Low Low On And Off Air Input ...

Page 20: ...on so perform all tests with the lever in Neutral position SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Low range doesn t work Pilot air line Remove the air line P at range valve Select low range at the knob There is air supply None There isn t air sup ply Check if there is air leakage through P air line Check if the knob is supplying air to air line P If not replace the knob Remove the air line P at...

Page 21: ... correctly assem bled Check the hoses if they are ok and there is no air flow replace the master control valve SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Deep range doesn t work Pilot air line Remove the air line SP at range valve Select deep range at the knob There is air supply None There isn t air sup ply Check if there is air leakage through SP air line Check if the knob is supplying air to air...

Page 22: ... is correctly assem bled Check the hoses if they are ok and there is no air flow replace the master control valve SYMPTOM COMPONENT PROCEDURE OUTPUT ACTION Shifting low range deep range is slow or doesn t work Air filter regulator Assemble the manometer in the output at the air fil ter Measure the output pres sure 7 3 bar 7 56 bar is the work pres sure Assemble the manometer at the air filter inpu...

Page 23: ...mble the exhaust valve and check if the spring is in the cor rect position accord ing to the picture end of this section If not correct the spring If the assembly is cor rect and the measures are out of specifica tion replace the exhaust valve Deep and Range valve If everything is OK during air filter and exhaust valve tests Disassemble the valve and inject air at 8 bar in the low high hole see pi...

Page 24: ...22 Component Test Procedures Correct Pin and Spring Assembling at Exhaust Valve Low and High Range Air Input Low and Deep Range Air Input ...

Page 25: ...the battery 10 Check if the light is blinking if yes proceed to procedure 2 below Note Nyogel is an electricity conductor gel must be applied with care to not cause short circuit between the terminals Procedure 2 1 Unplug the negative cable from battery 2 Turn off the vehicle and keep the key in the OFF position 3 Unplug the connector P1 and J1 from TCM 4 Plug P1 and J1 on P1B and J1B 5 Plug P1A a...

Page 26: ...nsor Follow Procedure 02 Put the ignition key at the off position Measure between the terminals 1 12 with a multimeter on Ohm position 600 a 800 Ohms 20ºC If the output is out of specification replace J2 the J2 from the harness If same output replace the transmis sion speed sensor If the output is OK replace the trans mission harness Follow Procedure 02 Disassemble the propeller shaft from the tra...

Page 27: ...ion 3 0 a 4 5 Vac If the output is out of specification replace J3 the J3 from the harness If same output replace the range switch If the output is OK replace the trans mission harness Follow Procedure 02 Engage low range Measure between the terminals 2 11 with the multimeter on Vac position 0 a 0 010 Vac If the output is out of specification replace J3 the J3 from the harness If same output repla...

Page 28: ...eplace the transmission harness 0 Vdc Replace the J6 by the J6 from the harness and measure again If the same output than before replace the deep range valve If the output between 22 and 26 V replace the transmission harness COMPONENT PROCEDURE OUTPUT ACTION Transmission Speed Sensor Follow Procedure 02 Put the ignition key at the off position Measure between the terminals 1 12 with a multimeter o...

Page 29: ...output replace the range switch If the output is OK replace the trans mission harness Follow Procedure 02 Engage low range Measure between the terminals 2 11 with the multimeter on Vac position 0 a 0 010 Vac If the output is out of specification replace J3 the J3 from the harness If same output replace the range switch If the output is OK replace the trans mission harness COMPONENT PROCEDURE OUTPU...

Page 30: ...28 Appendix Appendix Connector Pin Descriptions Note Connector diagram applies for both models FTS XX108LL FTS XX112L ...

Page 31: ...29 Appendix Appendix Wiring Diagrams for All Models FTS XX108LL ...

Page 32: ...30 Appendix FTS XX112L ...

Page 33: ...31 Appendix Appendix Air System Overview FTS XX108LL ...

Page 34: ...32 Appendix ...

Page 35: ...33 Appendix Appendix ...

Page 36: ...34 Appendix FTS XX112L ...

Page 37: ...35 Appendix Appendix ...

Page 38: ...36 Appendix ...

Page 39: ...rward Deep reduction Reduction button forward Low reduction Air Hose Hook Ups S port constant air supply HL port constant air supply P port range valve SP port deep range 3 Position Control Valve Position 1 Deep reduction Position 2 High range Position 3 Low range Air Hose Hook Ups 1 Supply line 3 Exhaust line 21 Deep pilot 22 Range pilot 23 Plug ...

Page 40: ...st Tool Breakout Box The breakout box warning lamp has the same behavior as the cabin warning lamp it lights for 2 second when the key is in the on position and flashes when the transmission is in downshift protection mode ...

Page 41: ... Range Switch a m p 9655 77 a m p 9655 77 a m p 9655 77 a m p 9655 77 P1A Connector DTM06 12SA J1A Connector DTM06 12SB J1B Connector DTM04 12SB J2 Connector Speed Sensor J7 Connector Deep Range Switch J8 Connector Range Valve J6 Connector Deep Range Valve DB 62 Female P1B Connector DTM04 12SA ...

Page 42: ...40 Appendix FTS XX112L ...

Page 43: ...41 Appendix Appendix ...

Page 44: ...AT II 1000V de Sobretensão e Dupla Isolação Tensão DC Faixas 400mV 4V 40V 400V 1000 V Precisão 400mV 1 5 6D 4V 400V 0 5 6D 1000V 1 0 4D Resolução 0 1mV 1mV 10mV 100mV 1V Impedância de Entrada 10MOaHMS na faixa de 400mV 40MOaHMS nas outras faixas Proteção de Sobrecarga 1000V DC 750V AC RMS Corrente DC Faixas 400µA 4000µA 40mA 400mA 20A Precisão 400µA 400mA 1 0 5D 20A 1 2 10D Resolução 0 1µA 1µA 10µ...

Page 45: ...l de ação rápida Resistência Faixas 400 OHMS 4k OHMS 40k OHMS 400k OHMS 4M OHMS 40M OHMS Precisão 400 OHMS 0 8 5D 4k OHMS 4M OHMS 0 8 4D 40M OHMS 1 2 5D Resolução 0 1 OHMS 1 OHMS 10 OHMS 100 OHMS 1k OHMS 10k OHMS Tensão de Circuito Aberto Aprox 400mV Proteção de Sobrecarga 250V DC Pico AC Freqüência Duty Cycle Somente Autorange Faixas 100 Hz 1kHz 10kHz 100kHz 1MHz 10MHz 30MHz Precisão 0 5 4D para ...

Page 46: ... their customers vendors and distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or mod ifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES ...