Eaton Transmission RTO-9109B-AT Service Manual

Troubleshooting Guide

Fuller Heavy Duty Transmissions

TRTS0020 EN-US

October 2007

RT-11109A-AT RT-11109A-ATR RT-11109A-ATS RT-12109A-AT RT-14109A-ATS RTO-11109A-AT RTO-11109A-ATS RTO-11109B-AT RTO-11109B-ATE RTO-11109B-ATR RTO-11109B-ATS RTO-12109A-AT RTO-12109B-AT RTO-13109A-ATE

RTO-13109B-AT RTO-13109B-ATE RTO-14109A-ATE RTO-14109A-ATS RTO-14109B-AT RTO-14109B-ATE RTO-14109B-ATS RTO-16109A-AT RTO-16109A-ATE RTO-16109B-AT RTO-16109B-ATE RTO-9109A-AT RTO-9109B-AT

For parts or service call us Pro Gear & Transmission, Inc.

1(877) 776-4600

[phone] [e-mail]

906 W. Gore St. Orlando, FL 32805

General Warnings:

Before starting a vehicle:

• 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:

•Place shift lever in neutral

•Set the parking brake

•Block the wheels

Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.

When parking the vehicle or leaving the cab:

• Place shift lever in neutral

• Set the parking brake

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 vehicle if alternator lamp is lit or if gauges indicate low voltage.

Suggested Tools:

Pressure Gauges:

•0-300 PSI Hydraulic gauge

•0-100 PSI Hydraulic gauge

•0-100 PSI Air gauge

OTC Tool & Equipment Division,

SPX Corporation

Eaton Part No.	Description
5505027	Volt /Ohm Meter (Standard
	commercially available VOM)

For ordering in U.S. and Canada call 1-800-533-0492. (In

Minnesota call 507-455-7010.)

MPSI Micro Processor Systems, Inc.

MPSI Part No.	Description
104004	Pro-link Main (MPSI hand-held diagnostic
	tool)
205040	Heavy Duty Multi-Protocol Cartridge (MPC)
805001	MPC Eaton Systems Software

For MPSI phone orders call 1-800-639-6774.

Related Publications

Installation Guide - Eaton TRIG-0020

Driver Instructions - Eaton TRDR-0020

Service Manual - Eaton TRSM-0020

Illustrated Parts List - Eaton TRIP-0023 (11109)

Eaton TRIP-0025 (13109)

Eaton TRIP-0022 (14109)

Eaton TRIP-0026 (16109)

For more information call 1-800-826-HELP (826-4357).

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.

Table of Contents

Section 1: Introduction

Diagnostics Procedure ...............................................	1-2
Fault Codes Retrieval/Clearing .....................................	1-3
Driving Techniques .....................................................	1-4
Fault Code Isolation Procedure Index ..........................	1-8
Symptom Driven Diagnostics ...................................	1-10
Section 2: Fault Isolation Procedures
Pretests
Electrical Pretest .........................................................	2-1
Pneumatic Pretest ......................................................	2-3
Power-Up Sequence Test ...........................................	2-4
Component and System Codes
Component Code 11, ECU ..........................................	2-6
Component Code 14, Shift Lever Fault ........................	2-8
Component Code 15, Shift Lever Data Link ...............	2-10
Component Code 21, Interrupt Solenoid Coil .............	2-16
Component Code 22, Lockup/Bypass
Solenoid Coil ............................................................	2-18
Component Code 23, Engine Speed Sensor ..............	2-20
Component Code 24, Hydraulic System Fault ............	2-24
Component Code 31, Engine Brake Relay Coil ...........	2-28
Component Code 32, Defuel Solenoid Coil ................	2-32
Component Code 33, System Voltage .......................	2-36
Component Code 34, Throttle Position Sensor ..........	2-38
System Code 35, Engine Control Failure
(Mechanically-Governed Engines) .............................	2-42
System Code 35, Engine Control Failure
(Electronically-Governed Engines) ............................	2-44
System Code 41, Range Failed to Engage ..................	2-48

Component Code 43, Range Solenoid Coil ................	2-50
Component Code 44, Disc/Inertia Brake
Solenoid Coil ............................................................	2-52
Component Code 45, Power Synchronizer
Band/Engine Boost Solenoid Coil ..............................	2-54
Component Code 51, Center Rail Sensor ...................	2-56
Component Code 52, Neutral Sensor ........................	2-60
Component Code 53, Gear Engaged Sensor ..............	2-64
Component Code 54, HI Range Sensor .....................	2-68
Component Code 55, LO Range Sensor ....................	2-72
Component Code 56, Input Speed Sensor .................	2-76
Component Code 57, Output Speed Sensor ..............	2-80
Component Code 61, Autoshifter Solenoid 1
Coil ..........................................................................	2-84
Component Code 62, Autoshifter Solenoid 2
Coil ..........................................................................	2-86
Component Code 63, Autoshifter Solenoid 3
Coil ..........................................................................	2-88
Component Code 64, Autoshifter Solenoid 4
Coil ..........................................................................	2-90
System Code 71, Stuck Engaged ..............................	2-92
System Code 72, Failed to Select a Rail .....................	2-96
System Code 73, Failed to Engage Gear ..................	2-100
System Code 74, Failed to Synchronize ...................	2-104
System Code 81, Invalid Shift Lever at Start
(Cable Only) ...........................................................	2-108
Component Code 82, Multiple Non-Adjacent Senors
(Cable Only) ...........................................................	2-110
System Code 83, Shift Lever Missing
(Cable Only) ...........................................................	2-112
Component Code 83, Shift Lever Missing
(Electronic Only) .....................................................	2-114

1-1

Table of Contents

Section 3: Symptom Isolation Procedures

Symptom Pretests

Transmission Basic Inputs Pretest ..............................	3-1
Engine Interface Pretest ..............................................	3-5
Symptom Tests
Shift Complaint Test ...................................................	3-7
High Operating Temperature Test .............................	3-14
Hand-Held Diagnostic Tool Failed to Operate Test .....	3-17
Shift Lever in Gear Signal Test ..................................	3-20
Neutral Output Test ..................................................	3-22
Splitshaft PTO Switch Test ........................................	3-24
Quick to Neutral Test ................................................	3-26
Shift Lever Auxiliary Output 2 Test ............................	3-27
Shift Lever Auto Neutral Input Test ...........................	3-29
Shift Lever Back Light Test .......................................	3-30
Reverse Relay Indicator Test .....................................	3-31
Start Enable Relay Test .............................................	3-34
Start Enable Relay Latch Test ....................................	3-40
Shift Lever Voltage Test (Driver Lever) ......................	3-42
Shift Lever Voltage Test (Work Lever) .......................	3-44

Appendix

Torque Converter Hydraulic Diagram ..........................	A-1
Pneumatic Diagram AT, ATR and ATS .........................	A-2
Pneumatic Diagram ATE .............................................	A-3
Pneumatic Diagram
Mechanical ATE with Throttle Boost ............................	A-4
Cable Shift Lever Wiring Diagram ...............................	A-6
Single Station Electronic Shift Lever Wiring Diagram ...	A-8
Dual Station Electronic Shift Lever Wiring Diagram ...	A-10
Cable Shift Lever Adjustment Procedure ...................	A-12
Linear Throttle Position Adjustment Procedure .........	A-14
Electro-Pneumatic Defuel Control
Adjustment Procedure ..............................................	A-15
Dual Station Start Enable ..........................................	A-16

1-2

1-1

Introduction

Diagnostics Procedure

Follow the flowchart below for all CEEMAT transmission failures. Perform tests and procedures as directed by the flowchart.

Key on.

Failure detected					• Perform Electrical Pretest
during self-check?			YES		(Page 2-1)
					• Perform Power-Up
					Sequence Test (Page 2-4)
NO

Retrieve active codes. (Page 1-3)

Active codes?

YES

NO

Retrieve inactive codes. (Page 1-3)

•Refer to the Fault Code Isolation Procedure Index (Page 1-8) to select a fault code isolation procedure

•Perform Electrical Pretest (Page 2-1)

Inactive codes?

YES

NO

Symptom?

YES

NO

•Record and clear codes (Page 1-3)

•Refer to the Fault Code Isolation Procedure Index (Page 1-8) to select a fault code isolation procedure

•Perform Electrical Pretest (Page 2-1)

•Perform Pneumatic Pretest (Page 2-3)

•Perform Electrical Pretest (Page 2-1)

•Perform Pneumatic Pretest (Page 2-3)

•Perform Transmission Basic Inputs Pretest (Page 3-1)

•Perform Engine Interface Pretest (Page 3-5)

•Refer to Symptom Driven Diagnostics Table (Page 1-10) to select a fault isolation procedure

Test complete.

1-2

Introduction

Fault Codes Retrieval/Clearing

Retrieving Fault Codes

Retrieve CEEMAT fault codes by enabling the CEEMAT system’s self-diagnostic mode.

Note: You can also use a diagnostic scan tool, such as the

MPSI Pro Link Main, to retrieve CEEMAT fault codes. Refer to the OEM’s documentation for more information.

1.Place the shift lever in neutral.

2.Set the parking brakes.

3.Turn the ignition key on but do not start the engine.

4.To Retrieve Active Codes: Start with the key in the on position. Turn the key off and on two times within five seconds ending with the key in the on position.

2 times off on

To Retrieve Inactive (Intermittent) Codes: Start with the key in the on position. Turn the key off and on four times within five seconds ending with the key in the on position.

4 times

off on

After a brief pause, the service transmission indicator lamp begins flashing two-digit fault codes.

5.Observe the sequence of flashes on the indicator lamp and record the codes. A one to two second pause separates each stored code, and the sequence automatically repeats after all codes have been flashed.

Clearing Fault Codes

The following procedure clears all inactive (intermittent) fault codes from the ECU’s memory. (Active fault codes are automatically cleared when the fault has been corrected.)

1.Place the shift lever in neutral.

2.Set the parking brakes.

3.Turn the ignition key on but do not start the engine.

4.Start with the key in the on position. Turn the key off and on six times within five seconds ending with the key in the on position.

6 times

off on

2 Flashes	1 Flash	3 Flashes	1 Flash
Short	(1–2 sec)		Short
pause			pause
(1/2 sec)			(1/2 sec)
Code 21			Code 31

DiagnosticsCodes Fault

ProcedureRetrieval/Clearing

1-3

Introduction

Driving Techniques

	Fault	Description	Type of Code	Driving Technique
	Codes
11		ECU	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
14		Shift Lever Fault	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat, vibration and
				selecting different shift lever positions.
15		Shift Lever Data Link	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
21		Interrupt Solenoid Coil	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
22		Lockup/Bypass Solenoid	Component	Key on. If the fault is present, the system should
		Coil		automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
23		Engine Speed Sensor	Component	Operate the vehicle above 4th gear until the fault occurs.
				Maintain a steady speed. If may be necessary to operate
				the vehicle for a prolonged period of time if the cause of
				the failure is related to heat or vibration.
24		Hydraulic System Fault	Component	Complete several automatic shifts while driving the vehicle
				through terrain that loads the engine.
31		Engine Brake Relay Coil	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
32		Defuel Solenoid Coil	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.

1-4

Introduction

Driving Techniques, continued

	Fault	Description	Type of Code	Driving Technique
	Codes
33		System Voltage	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
34		Throttle Position Sensor	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat, vibration and
				varying levels of throttle demand.
35		Engine Control Failure	System	Operate the vehicle and shift the transmission up and down
		(Mechanically-Governed		through the gears.
		Engines)
35		Engine Control Failure	System	Key on. If the fault is present, the system should
		(Electronically-Governed		automatically detect the problem and set the code.
		Engines)		If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat, vibration and
				varying levels of throttle demand.
41		Range Failed to Engage	System	Operate the vehicle and perform several range upshifts
				and downshifts. The failure is detected after 5 consecutive
				attempts to complete the same type of range shift. Several
				shifts (ten or more) may be necessary before the ECU
				confirms the failure.
43		Range Solenoid Coil	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
44		Disc/Inertia Brake Coil	Component	Key on. If the fault is present, the system should
				automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
45		Power Synchronizer	Component	Key on. If the fault is present, the system should
		Band/Engine Boost		automatically detect the problem and set the code.
		Solenoid Coil		If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
51		Center Rail Sensor	Component	Complete several front box gear shifts, including
				selections from NEUTRAL and automatic shifts while
				in motion.

Techniques Driving

1-5

Introduction

Driving Techniques, continued

	Fault	Description	Type of Code	Driving Technique
	Codes
52		Neutral Sensor	Component	Complete several front box gear shifts, including
				selections from NEUTRAL and automatic shifts while in
				motion.
53		Gear Engaged Sensor	Component	Complete several front box gear shifts, including
				selections from NEUTRAL and automatic shifts while in
				motion.
54		HI Range Sensor	Component	Complete several range shifts up and down across the
				entire range while the vehicle is in motion.
55		LO Range Sensor	Component	Complete several range shifts up and down across the
				entire range while the vehicle is in motion.
56		Input Speed Sensor	Component	Select a forward gear and drive at a steady speed for
				at least two minutes.
57		Output Speed Sensor	Component	Select a forward gear and drive at a steady speed for
				at least two minutes.
61		Autoshifter Solenoid 1	Component	Key on. If the fault is present, the system should
		Coil		automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
62		Autoshifter Solenoid 2	Component	Key on. If the fault is present, the system should
		Coil		automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
63		Autoshifter Solenoid 3	Component	Key on. If the fault is present, the system should
		Coil		automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.
64		Autoshifter Solenoid 4	Component	Key on. If the fault is present, the system should
		Coil		automatically detect the problem and set the code.
				If the fault is not present at key on, operate the vehicle and
				attempt to duplicate the driving conditions that triggered
				the fault code. Possible triggers include heat and vibration.

1-6

Introduction

Driving Techniques, continued

Fault	Description	Type of Code	Driving Technique
Codes
71	Stuck Engaged	System	Engage LO gear and allow the vehicle to slowly move
			forward. While the vehicle is in motion, move the shift
			lever to Reverse LO and slowly bring the vehicle to a stop.
			The vehicle will shift into Reverse LO. Several shifts (ten
			or more) may be required before the ECU confirms
			the failure.
72	Failed to Select a Rail	System	Complete several shifts while the vehicle is in motion,
			including selections from neutral. Also allow the
			transmission to complete several automatic shifts.
73	Failed to Engage Gear	System	Complete several shifts while the vehicle is in motion,
			including selections from neutral. Also allow the trans-
			mission to complete several automatic shifts.
74	Failed to Synchronize	System	Operate the vehicle at high speeds while shifting the
			transmission between 7th, 8th and 9th gears. Since the
			transmission makes several calculations before setting
			code 71, ten or more shifts may be required before the
			ECU confirms the failure.
81	Invalid Shift Lever at	System	Key on. If the fault is present, the system should
	Start (Cable Only)		automatically detect the problem and set the code.
			If the fault is not present at key on, operate the vehicle and
			attempt to duplicate the driving conditions that triggered
			the fault code. Possible triggers include heat and vibration.
82	Multiple Non-Ajacent	Component	Key on. If the fault is present, the system should
	Sensors (Cable Only)		automatically detect the problem and set the code.
			If the fault is not present at key on, operate the vehicle and
			attempt to duplicate the driving conditions that triggered
			the fault code. Possible triggers include heat, vibration and
			varying levels of shift lever positions.
83	Shift Lever Missing	System	Key on. If the fault is present, the system should
	(Cable Only)		automatically detect the problem and set the code.
			If the fault is not present at key on, operate the vehicle and
			attempt to duplicate the driving conditions that triggered
			the fault code. Possible triggers include heat, vibration or
			different lever positions.
83	Shift Lever Missing	Component	Key on. If the fault is present, the system should
	(Electronic Only)		automatically detect the problem and set the code.
			If the fault is not present at key on, operate the vehicle and

attempt to duplicate the driving conditions that triggered the fault code. Possible triggers include heat, vibration or different lever positions.

Techniques Driving

1-7

Introduction

Fault Code Isolation Procedure Index

	Fault	Description	Type of Code	Page
	Codes			Number
11		ECU	Component	2-6
14		Shift Lever Fault	Component	2-8
15		Shift Lever Data Link	Component	2-10
21		Interrupt Solenoid Coil	Component	2-16
22		Lockup/Bypass Solenoid Coil	Component	2-18
23		Engine Speed Sensor	Component	2-20
24		Hydraulic System Fault	Component	2-24
31		Engine Brake Relay Coil	Component	2-28
32		Defuel Solenoid Coil	Component	2-32
33		System Voltage	Component	2-36
34		Throttle Position Sensor	Component	2-38
35		Engine Control Failure (Mechanically-Governed Engines)	System	2-42
35		Engine Control Failure (Electronically-Governed Engines)	System	2-44
41		Range Failed to Engage	System	2-48
43		Range Solenoid Coil	Component	2-50
44		Disc/Inertia Brake Solenoid Coil	Component	2-52
45		Power Synchronizer Band/Engine Boost Solenoid Coil	Component	2-54
51		Center Rail Sensor	Component	2-56

1-8

Introduction

Fault Code Isolation Procedure Index, continued

	Fault	Description	Type of Code	Page
	Codes			Number
52		Neutral Sensor	Component	2-60
53		Gear Engaged Sensor	Component	2-64
54		HI Range Sensor	Component	2-68
55		LO Range Sensor	Component	2-72
56		Input Speed Sensor	Component	2-76
57		Output Speed Sensor	Component	2-80
61		Autoshifter Solenoid 1 Coil	Component	2-84
62		Autoshifter Solenoid 2 Coil	Component	2-86
63		Autoshifter Solenoid 3 Coil	Component	2-88
64		Autoshifter Solenoid 4 Coil	Component	2-90
71		Stuck Engaged	System	2-92
72		Failed to Select a Rail	System	2-96
73		Failed to Engage Gear	System	2-100
74		Failed to Synchronize	System	2-104
81		Invalid Shift Lever at Start (Cable Only)	System	2-108
82		Multiple Non-Anjacent Sensors (Cable Only)	Component	2-110
83		Shift Lever Missing (Cable Only)	System	2-112
83		Shift Lever Missing (Electronic Only)	Component	2-114

Code Fault

Procedure Isolation

Index

1-9

Introduction

Symptom Driven Diagnostics

Symptom	Isolation Procedure	Page
		Number
Shift complaint	Shift Complaint Test	3-7
High operating temperature	High Operating Temperature Test	3-14
Hand-held diagnostic tool failed to operate properly	Hand-Held Diagnostic Tool Test	3-17
Shift lever in gear signal not functioning properly	Shift Lever In Gear Signal Test	3-20
Neutral output not functioning properly	Neutral Output Test	3-22
Splitshaft PTO switch not functioning properly	Splitshaft PTO Switch Test	3-24
Quick to neutral not functioning properly	Quick to Neutral Test	3-26
Shift lever auxiliary output 2 not functioning properly	Shift Lever Auxiliary Output 2 Test	3-27
Shift lever auto neutral input not functioning properly	Shift Lever Auto Neutral Input Test	3-29
Shift lever back light not functioning properly	Shift Lever Back Light Test	3-30
Reverse relay indicator not functioning properly	Reverse Relay Indicator Test	3-31
Start enable relay not functioning properly	Start Enable Relay Test	3-34
Start enable relay latch not functioning properly	Start Enable Relay Latch Test	3-40
Shift lever voltage (Driver lever) not functioning properly	Shift Lever Voltage Test (Driver Lever)	3-42
Shift lever voltage (Work lever) not functioning properly	Shift Lever Voltage Test (Work Lever)	3-44

1-10

Fault Isolation Procedures

Electrical Pretest

	Step A	Procedure	Condition	Action

1.Key off.

2.Measure battery voltage at the battery terminals.

VOLTS

V COM A

+ –

If voltage is 11 to 13 volts		Go to Step B.
If voltage is outside of range		Repair or replace battery
		and/or charging system
		as required. Repeat
		this step.

	Step B	Procedure	Condition	Action

1.Key off.

2.Disconnect vehicle interface harness from CEEMAT.

3.Measure voltage between vehicle interface harness pin L and battery negative (–) terminal.

If voltage is within		Go to Step C.
1 volt of battery voltage

B	A	M			If voltage is outside of range	Repair or replace vehicle
C	P	N	L	VOLTS
				–	+	interface harness, battery
D R	V	U	K
E	S	T	J			circuit breaker or battery
				V COM A		circuit as required. Repeat
F	G	H
						this step.

	Step C	Procedure	Condition	Action

1.Key on.

2.Measure voltage between vehicle interface harness pin K and ground.

B A M

C P N L	VOLTS

D R V U K

E S T J

V COM A

F G H

Ground

If voltage is within				Go to Step D.
1 volt of battery voltage
If voltage is outside of range				Repair or replace vehicle
				interface harness, ignition
				circuit breaker or ignition
				circuit as required. Repeat
				this step.

Pretest Electrical

2-1

Fault Isolation Procedures

Electrical Pretest, continued

	Step D	Procedure	Condition	Action

1.Key off.

2.Disconnect positive battery cable.

3.Measure resistance between vehicle interface harness pin:

•B and battery negative (–) terminal.

•C and battery

negative (–) terminal.

B A M

OHMS

C P N L

D R V U K

V

COM A

E S T

J

If resistance is 0 to .3 ohms		Test complete.

If resistance is outside of range Repair or replace vehicle interface harness or ground connections as required. Repeat this step.

F G H

–

+

B A M

OHMS

C P N L

D R V U K

V

COM A

E S T

J

F G H

–

+

2-2

Fault Isolation Procedures

Pneumatic Pretest

Step A	Procedure		Condition	Action
	1.	Key off.
	2.	Install a 0-150 PSI air gauge
		in the regulated test port of
		the CEEMAT air filter/regulator.
	3.	Start engine.
	4.	Allow air pressure to build to
		governor cutoff.
	5.	Read vehicle main air pressure		Go to Step B.
		gauge.	If air pressure cuts off at
			90 to 120 PSI
			If air pressure is outside of	Repair vehicle air system
			range	as required. Repeat
		Regulated test port		this step.
Step B	Procedure		Condition	Action
	1.	Key off.
	2.	Monitor air pressure on vehicle	If vehicle maintains air pressure	Go to Step C.
		main air pressure gauge.
			If vehicle loses air pressure	Repair leak in vehicle
				air system. Repeat this step.
Step C	Procedure		Condition	Action
	1. Read air pressure gauge installed		If air pressure is 75 to 85 PSI	Test complete.
		in the air filter/regulator.
			If air pressure is outside of	Go to Step D.
			range
Step D	Procedure		Condition	Action

1.Key off.

2.Remove air supply line to the air filter/regulator and check air flow.

If air flows from the supply line		Replace air filter/regulator.
		Go to Step C.
If air does not flow from the		Repair vehicle air supply
supply line		to air filter/regulator.
		Go to Step C.

Pretest Pneumatic

2-3

Fault Isolation Procedures

Power-Up Sequence Test

	Step A	Procedure		Condition		Action
		1. Key on.
		2. Observe service transmission		If service transmission lamp
		lamp.				Test complete.
				lights for one second and
				goes off
				If service transmission lamp		Go to Step B.
				never comes on
				If service transmission lamp is		Go to Step C.
				on steady
	Step B	Procedure		Condition		Action

1.Key off.

2.Disconnect vehicle interface harness from CEEMAT.

3.Place jumper wire across vehicle interface harness pins G and B.

B A M

C P N L

D R V U K

E S T J

If service transmission lamp		Replace ECU.
turns on		Go to Step A.
If service transmission lamp		Repair or replace vehicle
never comes on		interface harness as
		required. Go to Step A.

F G H

	Step C	Procedure	Condition	Action

1.Key on.

2.Disconnect vehicle interface

connector at CEEMAT.		If service transmission lamp		Replace ECU.
		turns off		Go to Step A.
		If service transmission lamp		Repair or replace vehicle
		remains on		interface harness as
				required. Go to Step A.

2-4

Fault Isolation Procedures

Up-Power

Test Sequence

This Page left blank intentionally

2-5

Fault Isolation Procedures

Component Code 11

ECU

Fault Description

This code indicates an electrical problem inside the electrical control unit which is part of the ECU.

Required Tools

• CEEMAT Troubleshooting Guide

Likely Failed Components

Possible Causes

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

•Improper configuration software

•Faulty ECU

ECU

2-6

Fault Isolation Procedures

Code 11, ECU Test

Step A	Procedure			Condition		Action
	1.	Key on.
	2.	Retrieve codes (see page 1-3).		If code 11 is active		Replace ECU.
				If code 11 is inactive		Test complete.

11 Code

2-7

Fault Isolation Procedures

Component Code 14

Shift Lever Fault

Fault Description

This code indicates an electrical problem inside the electronic shift lever. The ECU detects this failure when it receives fault information from the electronic shift lever.

Required Tools

•Basic Hand Tools

•CEEMAT Troubleshooting Guide

Likely Failed Component

Possible Causes

This code is likely caused by a faulty shift lever.

Electronic shift lever (ESL)

2-8

Fault Isolation Procedures

Code 14, Shift Lever Fault Test

	Step A	Procedure	Condition	Action

1. Key on.

2. Retrieve codes (see page 1-3). If code 14 is active Replace electronic shift lever.

If code 14 is inactive		Test complete.

14 Code

2-9

Fault Isolation Procedures

Component Code 15

Shift Lever Data Link

Fault Description

This code indicates the CEEMAT ECU did not receive an updated shift lever status signal from the electronic shift lever via the J-1922 data link.

Required Tools

•Basic Hand Tools

•Digital Volt/Ohm Meter

•CEEMAT Troubleshooting Guide

Possible Causes

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

•Faulty J-1922 data link

•No electrical power to shift lever

•Faulty shift lever

•Faulty ECU

Likely Failure Locations

		PTO		Defuel	B A
	ECU				W4 ATA (+)
					W3 ATA(-)
J1	ressP	Neut Out		GND	W7 Eng Brake
			TPS		W15 Aux 1 Input
				Fuse	W16 Service Light Ground
					W1B Service Light (+)
					W6 Service Brake
					W1C Service Brake (+)
					W1 Ignition Power
		Typical vehicle interface harness
				(OEM supplied)
Electronic shift lever (ESL)
W1 VIGN
W2 VBAT
W13 GND
W24 LAMP_GND
W25 AUX_IN
W27 AUX_OUT1
W28 AUX_OUT2
Typical shift lever harness					ECU
(OEM supplied)
2-10

Fault Isolation Procedures

Code 15, Shift Lever Data Link Test

	Step A	Procedure	Condition	Action

1.Select the lever to be tested (driver or work lever).

2.Key off.

3.Disconnect connector from electronic shift lever.

4.Disconnect positive battery cable

5.Measure resistance between electronic shift lever harness

pin B1 and battery negative (–) terminal.

OHMS

A												A
1		2	3	4	5	6	7	8	9	10	11	12
B												B

If resistance is 0 to .3 ohms

If resistance is outside of range

Go to Step B.

Repair ground. Go to Step V.

V COM A

+ –

	Step B	Procedure	Condition	Action

1. Measure voltage between electronic shift lever harness pins A5 and B1.

VOLTS
A											A
1	2	3	4	5	6	7	8	9	10	11	12
B											B
V COM A

If voltage is within 1 volt of battery voltage

If voltage is outside of range

Go to Step C.

Repair harness to shift lever connector. Go to Step V.

	Step C			Procedure	Condition	Action

1.Measure voltage between electronic shift lever harness

pins A7 and B1.		If voltage is 0

If voltage is not 0

VOLTS
	A											A
	1	2	3	4	5	6	7	8	9	10	11	12
V COM A	B											B

Go to Step D.

Repair short to power or incorrectly wired circuit (should be ignition power).Go to

Step V.

15 Code

2-11

Fault Isolation Procedures

Code 15, Shift Lever Data Link Test, continued

	Step D	Procedure	Condition	Action

1.Key on.

2.Measure voltage between electronic shift lever harness

	pins A7 and B1.																																		If voltage is within 1 volt
																																			of battery voltage
																																			If voltage is outside of range
VOLTS
		A																												A
1						2	3			4		5				6	7		8	9		10						11		12
		B																												B

Go to Step E.

Repair ignition power line. Go to Step V.

VCOM A

	Step E			Procedure	Condition	Action

1.Measure resistance between electronic shift lever harness

pins B9 and B3.											If resistance is 0 to .3 ohms
											If resistance is outside of
OHMS											range
A											A
1	2	3	4	5	6	7	8	9	10	11	12
B											B

Go to Step F.

Repair open circuit between pins B9 and B3. Go to Step V.

V COM A

	Step F			Procedure			Condition		Action
				1. Check to see if there are			One shift lever		Go to Step H.
				two shift levers.
							Two shift levers		Go to Step G.

2-12

Fault Isolation Procedures

Code 15, Shift Lever Data Link Test, continued

	Step G	Procedure	Condition	Action

1.Disconnect connector from second electronic shift lever.

2.Measure resistance between electronic shift lever harness

pin B9 and ground.

OHMS

A											A
1	2	3	4	5	6	7	8	9	10	11	12
B											B

VCOM A

GROUND

If resistance is more than 10K ohms or infinite

If resistance is less than 10K ohms

Go to Step H.

Both levers selected. Repair wiring harness to pin B9 to ensure infinite resistance on non-selected lever. Go to Step V.

	Step H	Procedure	Condition	Action

1.Key off.

2.Disconnect J-1922 data link from engine ECM.

3.Disconnect harness from electronic shift lever.

4.Connect hand-held diagnostic tool.

5.Key on.

6.Select Perform Tests.

7.Select Throttle Dip Test.

8.Measure voltage between electronic shift lever pins A9

and A10 (connect positive lead to A10).

											VOLTS
A											A
1	2	3	4	5	6	7	8	9	10	11	12
B											B
											V	COM A

If voltage is +3.0 to +4.0 volts

If voltage is outside of range

Go to Step I.

Go to Step J.

15 Code

2-13

Fault Isolation Procedures

Code 15, Shift Lever Data Link Test, continued

	Step I	Procedure	Condition	Action

1.Activate Throttle Dip Test.

If voltage changes to		Replace shift lever.
–3.0 to –4.0 volts		Go to Step V.
If voltage does not change		Go to Step J.
to –3.0 to –4.0 volts

	Step J	Procedure	Condition	Action

1.Disconnect vehicle interface harness from CEEMAT.

2.Measure resistance between vehicle interface harness pin A and shift lever harness pin A10.

A	2	3	4	5	6	7	8	9	10	11	A	OHMS
1											12
B											B
												V COM A

B A M

C P N L

D R V U K

E S T J

F G H

3.Measure resistance between vehicle interface harness

				pin P and shift lever harness																															If resistance is 0 to .3 ohms
				pin A9.
																																			If resistance is outside of
A																							A												range
																													OHMS
1		2	3	4			5				6	7	8	9		10					11		12
B																							B
																													V COM A

Go to Step K.

Repair or replace J-1922 data link between electronic shift lever and CEEMAT. Go to Step V.

B A M

C P N L

D R V U K

E S T J

F G H

2-14

Fault Isolation Procedures

Code 15, Shift Lever Data Link Test, continued

	Step K	Procedure	Condition	Action

1.Measure resistance between vehicle interface harness pins:

•A to ground

•P to ground

B	A	M		OHMS
C	P	N	L
D R	V	U	K	V COM A
E	S	T	J
F	G	H		GROUND

B	A	M		OHMS
C	P	N	L
D R	V	U	K	V COM A
E	S	T	J
F	G	H		GROUND

If resistance is more than		Replace ECU. Go
10K ohms or infinite		to Step V.
If resistance is less than		Repair or replace vehicle
10K ohms		interface harness. Go
		to Step V.

15 Code

	Step V	Procedure			Condition		Action
		1.	Key off.
		2.	Reconnect all connectors.
		3.	Key on.
		4.	Clear codes (see Clearing
			Fault Codes, page 1-3).
		5.	Use Driving Technique
			to attempt to reset the code
			(page 1-4).
		6.	Check for codes
			(see Retrieving Fault Codes,		If no codes		Test complete.
			page 1-3).
					If code 15 appears		Return to Step A
							to find error in testing.
					If code other than 15 appears		Go to Fault Isolation
							Procedure Index (page 1-8).

2-15