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Automated
Transmissions
Air System
• Slave Valve and External Hoses
Eliminated
• This Eliminated Possible System Failure
Due to Failed Slave Valves, Air Hoses, Range & Splitter Cylinder Covers
and Leaks. • Modified to Accommodate Electric-
Over-Air Control Solenoids (Valves).
Base Model Changes
Main Case
• Added Mounting Provision for Shift Bar Housing
Transmission ECU • On Heavy-Duty Models, Added
Openings for Input Speed Sensor
and Mainshaft Speed Sensor.
Base Model Changes
Grease Lines
• Two separate grease hoses
• The housings are marked “RB” for release bearing and
“CS” for cross-shaft
UltraShift PLUS
Cross-Shaft Assembly
• 2 cross-shafts in the clutch housing, only upper requires grease
• Upper cross-shaft: located at 10 o’clock position
• Lower cross-shaft: attached to ECA
Auxiliary Bearing
• Updated with a thicker flange and smaller diameter than the standard
bearing
• Higher thrust capacity with new design
• Main case was modified to accept new bearing design
UltraShift PLUS
Combination Cylinder
• Used in VCS and VMS models
• Modified to allow for placement of the solenoid valves and
upgrades to the gasket to improve sealing
• Housing also contains 4 test ports to measure air pressure
in both cylinders on either side of the piston
Generation 2 Generation 3
• Began Production in 1999. • Began Production in 2006.
• Combined Shift Lever and System • ECU Count Reduced to One.
Manager ECU’s into a single • Transmission Controller and Shift
Pushbutton Shift Controller. Controller Combined.
• ECU Count Reduced to Two. • XY Shifter Rail Select Motor Re-Oriented.
• Inertia Brake Redesigned. • Transmission Harness Redesigned.
• Advanced Diagnostic Capability.
Clutch Types
DM Clutch
• Automatically Actuated
• Two-Pedal System
• Engaged Centrifugally by
Increasing Engine RPM
Solo Clutch
• Manually Actuated
• Three-Pedal System Electronic Clutch Actuation (ECA)
• Used to Open Clutch During Shifting
• Uses an Electronic Module with an
Integrated Electric Motor to Open
Clutch During Shifting
• Two-Pedal System
Current Models
AutoShift Models
• Require Use of Self-Adjusting Clutch, Electronic Engine w/J1939, and
an Engine Brake
• Three-Pedal System
• Medium-Duty
• AutoShift 6-Speed
• Heavy-Duty
• AutoShift 10-Speed
• AutoShift 18-Speed
UltraShift Models
• Fully Automatic
• Utilize a Centrifugal Master Clutch (Eliminates Need for Clutch Pedal)
• Medium-Duty
• UltraShift HV (available in 5 and 6-speed models)
• UltraShift HP (6-speed only)
• Heavy-Duty
• UltraShift LST (10-Speed)
• UltraShift LHP (13-Speed)
• UltraShift LEP (13-Speed)
Current Models (continued)
UltraShift PLUS Models
• Fully Automatic
• Utilize an electronic clutch actuator (eliminates clutch pedal)
• Clutch control is electronically managed and electronic engine shifts are
controlled via J-1939 data link
8-Speed
10-Speed
Basic Computer Control System
Overview
Four Functions of a Basic Computer Control System
• Input
• Processing
• Storage
• Output
Vehicle-Mounted Components
• (5) ECA Speed Sensor
• (6) Driver Interface Devices
• (7a) Brake Pedal
• (7b) Engine ECM
• (7c) Park Brake Switch
Speed Sensors
Speed Sensors
• Devices that Supply Information to the
Computer in the Form of a Voltage Signal
• Three Speed Sensors on AutoShift / UltraShift
Transmissions
• Confirmation of True Gear Engagement.
• Transmission ECU Can Determine If the
Transmission Range Section is in HI or LO
Based on Mainshaft Speed Compared to
Output Shaft Speed
• Transmission ECU Can Verify a Shift By
Reading the Change in Speeds Before and
After the Shift Event
Speed Sensors
OEM Devices
• Two Types of OEM Devices:
• Resistive-Ladder Controllers
• J1939 Controllers
Eaton Pushbutton Controller • Example: Freightliner SmartShift
• Communicates Operator Requested • OEM Shift Devices are Not Covered
Mode to Transmission ECU. Under Eaton Warranty.
• Gen 3 – No Longer Programmable
ECU.
Cobra Lever
• Available as Optional Driver
Interface Device.
• Wired Directly to the ECU.
• Analog, Resistive Ladder Input Device.
Other Inputs
Other Inputs That Influence System Operation
• Engine Electronic Control Module (ECM)
• Throttle Pedal Position
• Brake Switch Input
• Engine Torque Report
• Other External System ECU’s
• ABS
• VORAD
• Cab Controllers
Rail Motor
• Reversible DC Motor With a Worm Gear
Mounted On Motor Shaft.
• Moves Shift Finger From Side-To-Side To Select
Proper Shift Rail.
Gear Motor
• Reversible DC Motor With a Worm Gear
Mounted On Motor Shaft.
• Moves Shift Finger Front-And-Back To Engage
Front Box Gear.
Valves
Range Solenoid
• Replaces the Function of the Mechanical
Roadranger Valve and External Air System of
RT Gear Box.
• Mounted in the Range Cylinder Cover.
• Controls Air for Range Shifts.
• Responsible for Selecting HI or LO Range.
Splitter Solenoid
• Replaces the Function of the Mechanical
Roadranger Splitter Valve and External Air
System of RT Gear Box.
• Mounted in the Splitter Cylinder Cover.
• Controls Air for Splitter Shifts.
• Responsible for Selecting HI or LO Split.
Solenoids
• Both Solenoids Perform the Same Functions: All
Off, LO Range or Split, and HI Range or Split.
• Both are Identical. Contain the Same
Components. Operate the Same Way.
Inertia Brake
Inertia Brake
• Electrically Actuated Brake
• Slows Input Shaft Speed for Initial Gear
Engagement from Neutral
• Assists With Achieving Synchronous on
Upshifts
• Components:
• Ball Ramp
• Clutch Pack
• Coil
System is now at a
Steady State Engaged in
a Gear
Drive Mode
Driver Launches Vehicle and System Initiates Shift
(1) Driver Releases Clutch
(AutoShift)
(2) Use Fuel Pedal to
Engage DM Clutch
(UltraShift)
(3) ECA engages the clutch
(UltraShift PLUS)
(4) Trans ECU
Communicates with
Engine ECM Over J1939
(5) Trans ECU Monitors Input
Shaft Speed to Determine
Shift Points
Drive Mode
Driver Launches Vehicle and System Initiates Shift (continued)
Engine
Governed
Speed
Calculated
Synchronous
Speed (Based
On Shift Request)
Tone Sounds to
(3) When Manual Shift is Requested, Trans ECU Validates Signal Invalid
Request By Verifying Engine isn’t Over-Revved or Request
Over-Lugged
(4) Tone Sounds Signaling System Cannot Complete Request
if Completing Shift Would Result in Engine Over-Revving
or Over-Lugging.
Optional Modes of Operation
Manual Mode (continued)
Cruise Speed
Engine
Engine
Governed
Governed
Speed
Speed
+300 RPM
Limit
Forced Downshift
Engine Engine
Idle Idle
Speed Speed
Idle Speed
Cruise
Speed
Optional Modes of Operation
Low Mode (continued)
Engine Engine
Governed Governed
Speed Speed
+300 RPM
Limit
Before Working on a Vehicle or Exiting the Cab with the Engine Running
• Verify the Parking Brakes are Set.
• Verify Neutral is Selected on the Driver Interface Device.
• Verify the Wheels are Blocked.
System Codes
• Indicate a System Has
Failed to Respond as
Expected.
• Gen 3 Transmissions –
Service Light Flashes for
an Active System Code.
• Gen 1 and 2
Transmissions – Do Not
Flash Any Active
System Codes.
Fault Code Structure –
Building Blocks of Automation
Component Codes
• Indicate the Trans ECU
has Detected Electrical
Feedback Out-of-Range on
a Given Circuit.
• Caused by Vehicle or
Transmission Equipment.
• All Component Codes
Flash the Service Light on
All Automated Platforms.
Fault Isolation Techniques
Three Causes for All Component Codes
• Transmission ECU
• Transmission or Vehicle Harness
• Component for which the Code was Set
Clearing Codes
• Begin in the On Position
• Switch the Ignition Key Off and On Six Times
• The Key Clicks Must be Completed Within 5 Seconds
• Active Codes Cannot be Cleared
Key On Detection
Driving Detection –
System Needs to Function
Under Operating
Conditions to Detect a
Failure.
Specialty Tools
ServiceRanger Tool Bar
• Monitor Data
• Retrieve Fault Codes
• Advanced Product Functions
• Product Downloads
• Internet Downloads
• Information Main Menu
Specialty Tools
ServiceRanger Utilities Menu
• Check for Roadranger Products
• Reset Communications
• View / Change Communication
Settings
• View Current Downloads
• View Service Activity Reports
Specialty Tools
ServiceRanger Help Menu
• About
• Diagnostic Help
• Information Help
• Download Help
Snap-Shot
• Advanced Diagnostic Feature That Captures 31 Transmission and Engine Parameters
as Active Codes Occur.
• Parameters Include: Battery Voltage, Ignition Voltage, Input Shaft RMP, and Engine Load.
• Triggered When a Fault Becomes Active. Driver Can Also Manually Trigger a Snap-Shot.
Abeyance
• Managed by the Transmission ECU.
• Determines Exactly When to Log an Active Fault Code.
Electrical System Maintenance
Batteries and Cables
• Electrical pre-test
• Inspect cables for tightness and corrosion
Wiring Harnesses
• Check for proper routing
• Check for proper strain relief (flexibility or slack)
Data Link Construction and
Diagnostics
Data Links
• J-1587: low speed
• J-1939: high speed
• EPL: similar to J-1939, but no terminating resistors