Eaton Transmission RTLO-11118A-MT, RTLO-9118A MT Service Manual
Troubleshooting Guide
Fuller Heavy-Duty Transmissions
TRTS0011 EN-US
October 2007
RTLO-11118A-MT
RTLO-9118A-MT
For parts or service call us
Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
906 W. Gore St.
Orlando, FL 32805
Introduction
WARNING................................................................................................................2
Complaint Isolation, Verification & Remedy Procedure.............................................3
How to Use this Troubleshooting Guide...................................................................4
Complaint Diagnosis
Fault Code Diagnosis..............................................................................................6
Symptom Driven Diagnosis.....................................................................................7
Pre-Test
Transmission Electrical Test....................................................................................8
Performance Evaluation
Performance Evaluation Test.................................................................................10
Testing Procedures
Power Relay Coil Test..............................................................................................12
System Voltage Test................................................................................................13
Inertia Brake Solenoid Coil Test...............................................................................15
Inertia Brake Test....................................................................................................17
Inertia Brake Switch Test.........................................................................................18
Inertia Brake Air Supply Test...................................................................................19
Transmission Converter Open Lamp Test................................................................20
Engine Speed Sensor Test......................................................................................21
Bypass/Lockup Solenoid Coil Test..........................................................................23
Interrupt Clutch Solenoid Coil Test..........................................................................25
Hydraulic System Test............................................................................................27
Input Shaft Speed Sensor Test...............................................................................29
Output Shaft Speed Sensor Test.............................................................................31
Table of Contents
Appendix I
System Overview....................................................................................................33
Electrical Schematic................................................................................................34
Wiring Diagram (fold-out page)
1
Introduction
• Before starting a vehicle always be seated in the driver’s seat,
move the shift lever to neutral, and set the parking brakes.
• If engine cranks in any other gear than neutral, service your vehicle neutral safety start circuit and start enable relay circuit immediately.
• Before working on a vehicle or leaving the cab with engine running, place the transmission in neutral, set the parking brakes,
AND block the wheels.
• Do not release the parking brake or attempt to select a gear until
the air pressure is at the correct level.
• For safety reasons, always engage the service brakes when moving the shift lever from neutral to one of the other gear positions.
• When parking the vehicle or leaving the cab, always place the shift
lever in neutral and set the parking brakes.
• TOWING: To avoid damage to the transmission during towing,
place the transmission in neutral and lift the drive wheels off the
ground or disconnect the driveline.
Every effort has been made to ensure the accuracy of all information in this manual. However, Eaton
Transmission Division makes no expressed or implied warranty or representation based on the
enclosed information. Any errors or omissions may be reported to Training and Publications, Eaton
Transmission Division, P.O. Box 4013, Kalamazoo, MI 49003
2
Complaint Isolation, Verification & Remedy Procedure
Complaint
Identify System Error via Fault Codes
Using: Service Transmission Light
Service Transmission LIght
Able to Identify Fault Codes Observe and Record
Symptoms
Introduction
Utilize Trouble Shooting Guide
Fault Code Diagnosis
Isolate System or Component Failure
Follow Trouble Shooting Guide Test Sequences
PASS
Follow Trouble Shooting Guide
Remedy Sequence Instructions
Next Step in Trouble Shooting Guide
as Required for Further Diagnosis or Repair
Utilize Trouble Shooting guide
Symptom Driven Diagnosis
FAIL
Proceed to
Re-Test
3
Introduction
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
How To Use this Troubleshooting Guide
The purpose of this manual is to assist in the diagnosis and verification of your
electronically managed heavy-duty transmission system. It should be used in
conjunction with Eaton Driver Instructions, Illustrated Parts List, Installation
Guide, and Service Manual -- as well as OEM service related material.
This guide provides three functions:
1. Service Transmission Light Diagnostics: designed to lead the service techni-
cian to the source of a problem through flashing error codes.
2. Performance Evaluation: designed to lead the service technician to the source
of a problem through a performance evaluation.
3. Test and remedy Sequences: detailed component testing designed to isolate
and resolve system failures.
Service Transmission Light Diagnostics
The Service Transmission indicator light, which is also the torque converter
open lamp, assists the mechanic in problem diagnosis via flashing signals equal
to Fault Code numbers as listed in the Fault Codes Diagnosis section of this
manual.
If a driver reports a degraded mode of operation, advise that the capabilities of
the truck should be assessed and then taken to a service site. The transmission
temperature should be monitored during the trip to the service site.
Examples of potential problem conditions under which a vehicle with a Converter Enhanced Mechanical Transmission can be driven include:
• Transmission fails to lock torque converter, but vehicle can still proceed although
speed and/or power is limited.
• Transmission is not able to select all ratios and limits the gears available.
1. Using the Service Transmission Light for Diagnostics: To activate the retrieval
of fault codes via the Service Transmission light perform the following steps:
• Active Codes: Place the Shift Lever in Neutral. Set the parking brakes. Begin
with the key in the off position. Turn the key off and back on two (2) times within
5 seconds (OFF/ON/OFF/ON). It is OK if the engine stops, or continues running,
however do not re-energize the starter when retrieving Fault Codes as you may
cause codes to clear.
• If there are no active fault codes, then retrieve the intermittent codes.
• Intermittent codes: Follow instructions for Active Codes, but turn key OFF and
ON four (4) times.
• To clear fault codes: Follow instructions for Active Codes, but turn key OFF and
ON six (6) times. Fault codes should be cleared each time the transmission is
serviced.
4
1a. After activating the retrieval of codes, to read transmission errors via the Service Transmission
light, observe the sequence of flashes exhibited by the light. The Service Transmission light will
flash in coded sequences equal to Fault Codes identified in this manual. A long pause (5 seconds) follows each code before it is repeated, or the next codes sequence is given.
Examples:
• Flash / Pause / Flash = Fault Code 11 System Controller
• Flash - Flash / Pause / Flash - Flash - Flash = Fault Code 23 Engine Speed Sensor
• Flash / Pause / Flash - Long Pause - Flash - Flash / Pause / Flash - Flash - Flash = Fault Codes 11
& 23.
1b. To identify fault codes and applicable tests signalled by the Service Transmission light refer to
the Fault code Diagnosis section of this manual.
Symptom Diagnosis
1. Refer to the Performance Evaluation test in this manual.
2. Locate and perform appropriate Test Sequence as indicated by the Performance Evaluation Test.
Before Beginning Diagnostic Procedures
It is possible to “clear” or “reset” the Converter Enhanced Mechanical Electronic Control Unit
(ECU) for some transmission errors. If the transmission is not functioning properly try these
steps before beginning diagnostic procedures:
1. Stop the vehicle.
2. Place the shift lever in neutral.
3. Set the parking brakes.
4. Turn off the engine/ignition and wait for one minute.
5. Restart the engine.
6. Resume operation.
Introduction
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
Test Sequence and Remedy Sequence
1. Locate the correct Test Sequence.
2. Always perform pre-test procedures found at the top of each Test Sequence page before begin-
ning test procedure.
3. Follow test steps in sequence.
4. Go to Remedy Sequence when required.
5. Perform appropriate removal, replacement or adjustment procedures.
5
Fault
Code
Diagnosis
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
Fault
Code
Test Procedure Page
13 Power Relay Coil Test 12
15 Inertial Brake Solenoid Coil Test 15
22 Bypass/Lockup Solenoid Coil Test 23
23 Engine Speed Sensor Test 21
33 System Voltage Test 13
56 Input Shaft Speed Sensor Test 29
57 Output Shaft Speed Sensor Test 31
6
Symptom
If no fault codes exist perform the Performance Evaluation Test. Locate and perform appropriate
test sequence as indicated by the evaluation.
Driven
Diagnosis
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
7
Transmission
Electrical
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
Test
Measure voltage across vehicle battery
terminals [voltage = 12.6 volts].
Is voltage correct?
YES
Refer to Figure A below. Disconnect
vehicle interface harness connector J1
from ECU.
Refer to Figure B below. Measure resistance between pins A3, B3, C3, and battery negative terminal [resistance = 0.0-
0.4 ohms].
Is resistance correct?
YES NO
Refer to Figure B on
page 9.
Measure voltage
between harness
connector pins A3
and G2 [voltage =
battery voltage].
Is voltage correct?
A problem exists
with transmission electrical
grounds.
Contact OEM for
service information.
NO
Repair low voltage problem. Contact OEM
for service information.
YES
Refer to Figure B
below. Measure
voltage between
harness connector
pins A3 and G1
[voltage = 0 volts.]
Is voltage correct?
YES NO
CONTINUE
NO
A problem exists
in vehicle interface harness or
batter supply circuit breaker. Contact service
information.
A problem exists
in vehicle interface
harness or ignition
voltage supply circuit breaker. Contact OEM for
service information.
8
Continuation
Turn the ignition key “ON”.
Refer to Figure B on page 12.
Measure the voltage between
the harness connector pins A3
and G1 [voltage = battery voltage]. Is voltage correct?
YES NO
Turn ignition key “OFF”. A problem exists in vehicle interface har-
ness or ignition voltage supply circuit
breaker. Contact OEM for service information.
Transmission
Electrical
Test
For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.
Refer to Figure B below. Place
jumper wire across vehicle
interface harness connector
pins F1 and A3.
Refer to Figure B below. Measure voltage between harness
connector pins B3 and E1 [voltage = battery voltage]. Is volt-
age correct?
YES
Refer to Figure A on page 8.
Disconnect vehicle interface
harness J2 connector from
ECU.
Refer to Figure C on page 12. Measure
voltage between J1 connector pin B3
and J2 connector pin A3 [voltage = battery voltage]. Is voltage correct?
YES
NO
A problem exists in transmission power relay or vehicle
interface harness. contact
OEM for service information.
NO
Test complete
Repair/replace vehicle interface harness according to OEM service
information.
9
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