Eaton Fuller Hybrid Transmission Fault Code 61 – Rail Select Motor

Fault code for Eaton Hybrid Drive Systems models (MY08) EH-8E306A-U, EH-8E306A-UPG, EH-8E306A-UP, EH-8E306A-CD, EH-8E306A-T, EH-6E606B-CD, the Electric Shifter contains two electric motors—the Rail motor and Gear motor. These motors move a shift finger between the various rails which engage the shift rails. Power is supplied from the Transmission Electronic Control Unit (TECU). Read below to learn how to test, clear and fix fault code errors for your Freightliner, Mack, Peterbilt, Kenworth, Volvo, International, and heavy-duty truck and equipment. The DC/DC Converter is connected to the Power Electronics Carrier (PEC), which provides 340 volts DC. The voltage is reduced to 12-volts DC and maintains the 12-volt system during engine off PTO operation. The DC/DC maintains a steady 14.2 (±0.2) (MY08 Systems) or 12.6 (MY09 System) volts output and increases the amperage with vehicle demand up to 1.5 kw or 120 amps.

Fault Code 61 – Rail Select Motor Detection

The following preconditions must be met before the system detects the fault:

  • TECU ignition voltage is greater than 7 volts and less than 16 volts.
  • TECU System Battery Voltage Low Fault is Inactive.
  • TECU System Battery Voltage Weak Fault is Inactive.
  • Electric Shifter is not energized and the shift finger is not moving.

Note: When troubleshooting an Inactive code refer to the Product Diagnostic Mode (PDM)

Conditions to Set Fault Code Active

  • FMI 5 and 6 are set when the TECU detects 5 continuous open or short conditions on the Electric Shifter while the motor drive circuit is idle in a 500 ms interval.

Fallback When Fault Code 61 is set the following conditions occur:

  • Red “Service” light illuminates and an “F” flashes in the gear display.
  • Fault is stored in TECU memory.
  • The operation mode changes to “AutoShift Fallback” mode.
  • If this fault occurs while moving, the transmission remains in the current gear and the clutch opens when the vehicle stops.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours and the HCM automatically clears the faults from history after the fault has been Inactive for 200 hours.

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

  • FMI 5, 6
    • Electric Shifter
    • TECU
    • Transmission Harness

Fault Code 61 – Rail Select Motor Test

Component Identification:

Harness Front View TECU - Vehicle Interface Connector

Harness Front View
(TECU – System Interface Connector)

Eaton Fuller transmission rail select motor

Harness Front View
(Rail Select Motor

NOTE: Refer to the Eaton Hybrid Component and Connector Location for Connector Locations in MY08 Systems

TECU Rail Select Motor Connector location on Eaton Fuller transmission

STEP 1.Verify continuity of Transmission Harness circuits.

  1. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.
  2. Key off.
  3. Disconnect negative battery cable.
  4. Disconnect the Transmission Harness 38-Way Connector from the TECU.
  5. Measure resistance between the Transmission Harness 38-Way Connector Pin 35 and Pin 37:
    • If resistance is 0.3–150 ohms, go to Step 2.
    • If resistance is outside of range, go to Step 3.

STEP 2. Verify continuity of Transmission Harness circuits to ground.

  1. Measure resistance between the Transmission Harness 38-Way Connector Pin 35 and ground:
    • If resistance is 10K ohms or greater, replace Transmission Electronic Control Unit (TECU)(Only if Fault Code is Active), then go to Step 4.
    • If resistance is less than 10K ohms, go to Step 3.

STEP 3. Verify continuity of Rail Select Motor Harness circuit.

  1. Disconnect 2-Way Rail Select Motor Connector from the Transmission Harness.
  2. Measure resistance between Rail Select Motor Harness 2-Way Connector Pin A and Pin B and Pin A to ground:
    • If resistance between Pin A and Pin B is 0.3–150 ohms and Pin A to ground is 10K ohms or greater, replace Transmission Harness, then go to Step 4.
    • If resistance is outside of range, replace Electric Shifter, then go to Step 4.

STEP 4. Verify repair.

  1. Key off.
  2. Reconnect all connectors and the negative battery cable.
  3. Key on.
  4. Clear codes, see Clear Inactive Faults.
  5. Drive the vehicle and attempt to reset the code.
  6. Check for codes, see View Active and Inactive Faults.
    • If no codes, test is complete.
    • If fault Code 61 appears, find error in testing, go to Step 1.
    • If a code other than 61 appears, see Fault Code Index List.
Warnings & Cautions

Danger: Danger indicates you will be severely injured or killed if do not follow the indicated procedure.
Warning: Warning indicates an immediate hazard, which could result in severe personal injury if you do not follow the indicated procedure.
Caution: Caution indicates vehicle or property damage could occur if you do not follow the indicated procedure.

Note: Note indicates additional detail that will aid in the diagnosis or repair of a component/system.

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

1. If the high-voltage cones are around the vehicle and the lockout is installed on the PEC, the only person that should be allowed to start the vehicle is the person who signed the lockout tag.
2. Before working on a vehicle or leaving the cab while the engine is running, you should place the shift lever in “N” set the parking brake, and block the wheels.
3. For safety reasons, always engage the service brakes prior to selecting gear positions from “N.”
4. Before starting a vehicle always be seated in the driver’s seat, select “N” on the shift control, and set the parking brakes.
5. In vehicles with ePTO, the engine and/or
Motor/Generator can start in ePTO mode. Never perform any maintenance or work on vehicle, while in this mode.
6. 12-Volt Battery positive (+) and negative (-) must be disconnected prior to any welding on any Hybrid equipped vehicle.

Caution: Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.
Caution: Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.
Caution: To avoid damage to the transmission during towing place the shift lever in “N” and lift the drive wheels off the ground or disconnect the driveline.

High-Voltage Warnings & Cautions

  • Use CO2 or Dry Chemical Fire Extinguishers.
  • The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with warning labels at the connectors.
  • All Eaton® Hybrid Diesel/Electric vehicles will be marked ‘Hybrid’ on the outside of the vehicle, along with the shift label on the dash.
  • Refer to OEM for specific location of chassis mounted hybrid components.
  • Do NOT cut into the orange high-voltage cables.
  • Do NOT cut into or open the PEC.
  • Do NOT cut into or open the DC/DC Converter.
  • Do NOT cut into or open the Inverter.

A buffer zone must be set up and high-voltage insulated rubber gloves (class 0 with leather protectors) are required prior to working on high-voltage. Failure to follow these instructions may result in severe personal injury or death.
The rubber-insulated gloves that must be worn while working on the high-voltage system are class 0 with leather protectors. The rubber gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in “Diagnostic Tools/Service Publications” on page 6. Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 should be followed. Failure to follow these instructions may result in severe personal injury or death.
The Lockout and Tagout devices should only be removed by the technician that placed the Lockout and Tagout devices on the vehicle. Failure to follow these instructions may result in severe personal injury or death.
High-voltage rubber insulated gloves (class 0 with leather protectors) must be worn when working on any
high-voltage cables. The “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 must be followed prior to removing any high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.
High-voltage cables and wiring are orange and contain a warning label at the connectors. High-voltage components are marked with a label. High-voltage rubber insulated gloves (class 0 with leather protectors) must be used when working on any of these components. Failure to follow these instructions may result in severe personal injury or death.

High-Voltage Service Shutdown Procedures

High-Voltage Service Shutdown and Power-Up Procedure1. Follow “High-Voltage Work Area” procedure.
2. Locate the red PEC Service Switch on the front of the PEC and push switch off.
3. Remove the Service Switch Cover and install the Lockout Bracket (J48506).
4. Fasten tag to the Lockout Bracket.
5. Ensure the PEC Service Switch can not move from the off position.
6. Allow the system to set for a minimum of 5 minutes to discharge high voltage.
7. Connect ServiceRanger and view the Data Monitor PID 116 called “High-Voltage Battery Potential.” Use SPN 520323 for J1939 connection “Battery Voltage RB” (Relay Box).
8. The voltage should be 30 volts or less. If the voltage is above 30 volts, do not work on the vehicle and contact Eaton® at 1-800-826-HELP (4357).
9. Turn ignition key off and proceed to repair or troubleshooting step.
Note: The voltage drops to zero when the key is off.

High-Voltage Service Power-Up Procedure

1. Install all high-voltage connectors into their locked positions.
2. If you are the person working on the vehicle, remove the Lockout Bracket and tag.
3. Reinstall the Lockout Bracket over the Service Switch.
4. Pull the Service Switch out and let vehicle set for 2 minutes.
5. Start vehicle when appropriate.

Eaton Hybrid Component and Connector Location

Eaton Hybrid Component and Connector Locations MY08 Systems

Eaton Hybrid Component and Connector Location MY09 Systems

Eaton Hybrid Component and Connector Locations MY09 Systems

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