Fuller Heavy Duty Transmissions

More time on the road

Installation Guide
Fuller Heavy Duty Transmissions
TRIG0070

October 2007
RTLO-11610B RTLO-11610B-T2 RTLO-12610B RTLO-12610B-T2 RTLO-12713A RTLO-12913A RTLO-13610B RTLO-13610B-T2 RTLO-14610A RTLO-14610B RTLO-14610B-T2 RTLO-14613B RTLO-14618A RTLO-14713A RTLO-14718B RTLO-14913A RTLO-14918B RTLO-14918B-T2 RTLO-15610B RTLO-15610B-T2 RTLO-16610B RTLO-16610B-T2 RTLO-16618A RTLO-16713A RTLO-16713A-T2 RTLO-16718B RTLO-16913A RTLO-16913A-T2 RTLO-16918B RTLO-16918B-T2 RTLO-17610B RTLO-17610B-T2 RTLO-18610B RTLO-18610B-T2 RTLO-18718B RTLO-18718B-T2 RTLO-18913A RTLO-18913A-T2 RTLO-18918B RTLO-18918B-T2 RTLO-20913A RTLO-20918B RTLO-20918B-T2 RTLO-22918B RTLOC-16909A-T2 RTLOF-11610B RTLOF-11610B-T2 RTLOF-12610B RTLOF-12610B-T2 RTLOF-12713A RTLOF-12913A RTLOF-13610B RTLOF-13610B-T2 RTLOF-14610B RTLOF-14610B-T2 RTLOF-14613B RTLOF-14618A RTLOF-14713A RTLOF-14718B RTLOF-14913A RTLOF-14918B RTLOF-14918B-T2 RTLOF-15610B RTLOF-15610B-T2 RTLOF-16610B RTLOF-16610B-T2 RTLOF-16618A RTLOF-16713A RTLOF-16713A-T2 RTLOF-16718B RTLOF-16913A RTLOF-16913A-T2 RTLOF-16918B RTLOF-16918B-T2 RTLOF-17610B RTLOF-17610B-T2 RTLOF-18610B RTLOF-18718B RTLOF-18913A RTLOF-18913A-T2 RTLOF-18918B RTLOF-18918B-T2 RTLOF-20913A RTLOF-20918B RTLOF-20918B-T2 RTLOF-22918B RTLOFC-16909A-T2

Warnings and Cautions

Warnings and Cautions

The description and specifications contained in this service publication are current at the time of printing. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.

Important Notice
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used.

WARNING

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage. Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.
CAUTION

Failure to follow indicated procedures may cause component damage or malfunction.

IMPORTANT

Highly recommended procedures for proper service of this unit. Note: Additional service information not covered in the service procedures. Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts. Every effort has been made to ensure the accuracy of all information in this guide. However, Eaton makes no expressed or implied warranty or representation based on the enclosed information.

Table of Contents

Warnings and Cautions Table of Contents

Warnings and Cautions ...............................................i

Electrical Requirements
Top 2 Valve Electrical Requirements ........................ 18 Wiring Diagram OEM Responsibility ........................ 19 Caterpillar Programming ...................................... 19 Detroit Diesel Programming ................................. 21

General Information
How to Use This Manual ............................................1

Installation Requirements
Requirements .............................................................2 Space Requirements ..................................................3 10-speed Valve Location ........................................3 9- / 13-speed Valve Location ..................................5 18-speed Valve Location ........................................6 Lubrication Requirements ..........................................8 Air Supply Requirements ..........................................10 9-speed Pneumatic Diagrams ...............................11 10-speed Pneumatic Diagrams .............................12 13-speed Pneumatic Diagrams .............................13 18-speed Pneumatic Diagrams .............................14 Transmission Mounting Requirements ....................15 Mounting Transmission to Engine ........................16 Using Rear Supports ............................................17 Typical Rear Support Designs ...............................17

Line Inspection
Line Inspection and Road Test Instructions ............. 26 Line Inspection Form ............................................... 27 Troubleshooting ....................................................... 28

Appendix
Wiring Diagrams ...................................................... 29 Caterpillar ............................................................. 29 Detroit Diesel ........................................................ 31 Torque Specifications .............................................. 33 Suggested Tools ...................................................... 34 Related Publications ................................................ 34 Application Forms .................................................... 35

General Information

How to Use This Manual

This Eaton Publication is intended to be a reference guide for the installation of all Top 2 series transmissions. As much general vehicle and transmission information has been given for covering the wide range of applications. This information benefits the OEM installer by providing the correct installation procedures to ensure the utmost in satisfactory operation and long service life. For specific engine information, contact engine OEM. Specific OEM installation requirements are shown in each section. Failure to adhere to Eaton installation requirements may effect transmission performance and/or warranty coverage. Top 2 transmissions installed at OEM facilities must meet the requirements for standard manual Eaton Fuller transmissions outlined in Form FUL-169. Applications outside of these requirements must be approved by Eaton Engineering using Form FUL-170. All information contained in this manual was accurate at the time of printing. With each new application, engine manufacturers should be contacted to make sure desired engines are compatible with the Top 2 system.

Installation Requirements

Requirements
All Top 2 transmission systems installed at OEM facilities must meet the requirements for standard manual Eaton Fuller Transmissions outlined in Form FUL-169 and be approved using the Eaton Automated Transmission Application Approval Form FUL-170. Both forms can be found in the Appendix. 1. 2. 3. 4. 5. 6. 7. 8. Air Dryer Requirements - A high quality commercially available vehicle air dryer is required to be used in conjunction with Top 2 systems. Clutch Requirements - Spring dampened clutches are required for all applications. Electrical Requirements - All wires are to be a minimum of 16 gauge GXL. Integral Coolers - Reference Form FUL-169 Note 2 for transmission cooler requirements. Line Inspection - All Eaton Top 2 transmission systems installed at OEM plants must pass the requirements outlined in the Line Inspection Form prior to shipment. Lubrication Requirements - Transmission oil should meet specifications as outlined in TCMT-0020 (Roadranger Products Approved Lubricants) and TCMT-0021 (Roadranger Products Lubrication Manual). Power Connections - All ECMs will have redundant power and ground pins. If no redundancy is available, a relay connection similar to the one on page 29. Valve Spatial Requirements - The Top 2 solenoid valve requires a minimum of 2 clearance from any high temperature devices (i.e. exhaust crossover pipes).

Installation Requirements
2

Installation Requirements

Space Requirements
10-speed Valve Location
Note: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.

Installation Requirements

Installation Requirements

MODEL 11610 12610 13610 14610 15610 16610

LENGTH A 815.1 (32.09) 815.1 (32.09) 815.1 (32.09) 823.2 (32.41) 823.2 (32.41) 823.2 (32.41)

LENGTH B 200.4 (7.89) 200.4 (7.89) 200.4 (7.89) 208.5 (8.21) 208.5 (8.21) 208.5 (8.21)

LENGTH C 67.8 (2.67) 67.8 (2.67) 67.8 (2.67) 75.9 (2.99) 75.9 (2.99) 75.9 (2.99)

Installation Requirements

9- / 13-speed Valve Location

Note: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.

Installation Requirements

MODEL 12713 14713 16713 12913 14913 18913

LENGTH A 815.1 (32.09) 823.2 (32.41) 823.2 (32.41) 840.7 (33.09) 840.7 (33.09) 840.7 (33.09)

LENGTH B 200.4 (7.89) 208.5 (8.21) 208.5 (8.21) 226.1 (8.9) 226.1 (8.9) 226.1 (8.9)

LENGTH C 43.9 (1.73) 51.8 (2.04 46.5 (1.83) 69.6 (2.74) 69.6 (2.74) 69.6 (2.74)

Installation Requirements

18-speed Valve Location

Note: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.

Installation Requirements

MODEL 14918 16918 18918 20918 22918

LENGTH A 840.7 (33.09) 840.7 (33.09) 840.7 (33.09) 840.7 (33.09) 840.7 (33.09)

LENGTH B 226.1 (8.9) 226.1 (8.9) 226.1 (8.9) 226.1 (8.9) 226.1 (8.9)

LENGTH C 69.6 (2.74) 69.6 (2.74) 69.6 (2.74) 69.6 (2.74) 69.6 (2.74)

Installation Requirements

Lubrication Requirements
Eaton Fuller transmissions are designed so the internal parts operate in a bath of lubricant circulated by the motion of gears and shafts. Thus, all parts will be amply lubricated if these procedures are closely followed: Use Roadranger CD50 or equivalent E500 synthetic per Eaton publication TCMT-0021. When adding lubricant, types and brands of lubricant should not be mixed because of possible incompatibility. Use clean lubricant and clean containers when filling the transmission. Containers that have been used for antifreeze or water should not be used for transmission lubricant. Additives and friction modifiers are not recommended for use in Eaton Fuller transmissions.

Installation Requirements

Recommended Lubricant
Type Roadranger CD50 Transmission Fluid Grade (SAE) 50 Temperature ALL

Includes all Roadranger Approved comparable synthetic lubricant.

Proper Lubricant Level Transmission Capacity

9-Speed 10-Speed 13/18-Speed 28 pints (13.2 liters) 26 pints (12.3 liters) 28 pints (13.2 liters)

Note: Failure to adhere to Eaton Installation Requirements may effect transmission performance and /or warranty coverage. Note: The quantity for proper fill level will vary from model to model. Make sure lubricant is level with fill hole opening. Because you can reach lubricant with your finger does not mean lubricant is at the proper level. (On heavy duty transmissions, one inch of lubricant level equals about 8 pints of oil).

Hole

Hole

Improper Oil Level

Proper Oil Level

Installation Requirements

Proper Lubrication Levels as Related to Transmission Installation Angles

If the transmission operating angle is more than 12 degrees, improper lubrication can occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For example: If you have a 4 degree transmission mounting angle, then 8 degrees (or 14 percent of grade) is equal to the limit of 12 degrees. If you have a 0 degree mounting angle, the transmission can be operated on a 12 degree (21 percent) grade. Note: The chart shows the effect a lubricant level 1/2 below normal can have on safe operating angles. Operating the vehicle 1/2 low on lubricant reduces the safe degree of grade by approximately 3 degrees (5.5 percent).
Proper Lubrication Levels are Essential!
22 20 18 16
TR TR AN SM

12o 11o 20'

IS SI ON OI

10o 13'
LL EV EL TO

9o 16'
BO TT OM

Limitations for Proper Lubrications Percent of Grade

AN

14 12 10 8 6 4 2 0 0o

SM

IS

SI

8o
OF FI LL ER

ON

OI

2Q

LL

EV S

6o 51'
HO LE

UA

EL LO

RT

1/

2"

BE

5o 48' 4o 35'

LO

FI

LL

ER

HO

LE

3o 26' 2o 18' 1o 8'

1o

2o

3o

4o

5o

6o

0o 7o

Transmission Mounting Angle Dotted line showing "2 Quarts Low" is for reference only. Not recommended.

Note: For transmissions with coolers installed, make sure lubricant is level with fill hole opening, run the truck, stop and check lubricant level. Lubricant must be level with fill hole.

Percent Grade Converted to Degrees

Installation Requirements

Air Supply Requirements

1. 2. 3. 4. 5. 6. 7. It is required to use a high quality commercially available air dryer in the air supply line before the transmission. Minimum air requirement for the transmission is 65 PSI. A minimum of 1/4 diameter air supply line is required. The transmission air supply is required to be routed from the air tank, which supplies air to either the front or rear vehicle service brakes, with a gauge indicator in the cab. Transmission airlines should not be routed or attached at the bottom air tank fittings to avoid any chances of introducing moisture into the airline. Care should be used when routing the air supply to avoid kinks and close contact to heat sources. The transmission air supply must be connected to the air filter/regulator mounted on the range cylinder cover.

Installation Requirements

Note: The air filter/regulator must not be removed during installation. 8. Air additives such, as alcohol devices should not be permitted to enter the transmission air supply. Additives could cause damage to air system components, which could lead to degraded transmission performance.

Air Drying
SERVICE TANK

Compressor

CAUTION

Do not tie wrap air line to wire harness on transmission

10

Installation Requirements

9-speed Pneumatic Diagrams

Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

Roadranger valve

HI Range Inactive LO Range Pressured 5/32" or 1/8" air line

5/32" or 1/8" air line

HI Range Pressured LO Range Inactive

Constant regulated air (55-65 PSI) S 5/32" air line

H Slave Valve

L S L P

Air filter/ regulator Top 2 Solenoid Valve P1 P2 5/32" air line HI Split Pressured LO Split Inactive 5/32" air line

1/4" air hose

HI Range Inactive LO Range Pressured

1/4" air hose S EXH Constant regulated air (55-65 PSI) Constant regulated air (55-65 PSI) 1/4" air hose

Splitter Cylinder

Range Cylinder 1/4" air hose

Lock High Except During Top 2 Function

11

Installation Requirements

10-speed Pneumatic Diagrams

Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

Installation Requirements
12

Installation Requirements

13-speed Pneumatic Diagrams

Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

13

Installation Requirements

18-speed Pneumatic Diagrams

Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.

Installation Requirements
14

Installation Requirements

Transmission Mounting Requirements

Handling
Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components. 1. Use a hoist or transmission jack that permits precise control of transmission movement during installation.

Transmission Preparations
Always remove banding and protective wrapping from the transmission and inspect for shipping damage as soon as possible upon receiving. 2. If a thread-in electronic speedometer system is used, tighten sensor or sensor lock nut to 35 lbs-ft. [47 Nm], (3/4-16 threads). If a push-in electronic speedometer system is used, Eaton P/N 14142 (O-ring) and Eaton P/N 71206 (silicon lubricant) are used to seal the sensor. To remove, reposition, or replace rear bearing cover, apply Eaton Sealant P/N 71205 or equivalent to threads and tighten main shaft rear bearing cover capscrews to 35-45 lbs-ft. [47-61 Nm] (3/8-16).

3.

Output Yoke/Flange Installation

Note: The output yoke/flange is supplied with the transmission. If the output Yoke/flange must be replaced, the following procedure should be followed. (For detailed instructions, refer to the proper transmission model service manual.) Select the proper output yoke per specified application, remove plastic cover, and inspect the slinger (gold anodized ring) and seal surface for damage or contamination. Do not use the yoke/flange if the slinger or seal surface is damaged such as dents, nicks, or scratches. 1. 2. Prior to installation, remove all contamination such as styrofoam particles, dust, dirt, or rust in the machined surface of the yoke/flange. Place the yoke/flange over the transmission output shaft end and rotate it to line up the splines. Take care not to bump any machined surface of the yoke/flange against the output shaft. Push the yoke all the way onto the output shaft and onto the seal with one continuous motion. Thread the tail shaft nut onto the tailshaft until nylon insert is engaged on the tailshaft thread. Secure yoke/flange and tighten the tailshaft nut to 450-500 lbs-ft. [610-678 Nm].

3.

15

Installation Requirements

Mounting Transmission to Engine

Use the two transmission lifting eyes provided. The lifting eye position must not be changed on the transmission. Note: For lifting eye and sensor retaining bolt locations, see Appendix. These bolts can not be used for brackets or for any other purpose. 1. 2. Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs. Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure engine flywheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of damage before installation. Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmission must be in gear in order to rotate the input shaft by turning the output shaft/yoke. Adjust the lift chain or transmission jack to obtain the same relative angle as the engine. The face of the engine flywheel housing and the face of the transmission clutch housing must be parallel during installation. If the transmission is properly aligned and the clutch is installed properly, very little force is required to slide the input shaft through the clutch and into the pilot bearing. If interference is encountered, move the transmission away from the engine to investigate the cause. The use of excessive force to overcome misalignment may cause damage to the transmission input shaft and the clutch. Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines. Once the transmission is seated against the engine flywheel housing, align the clutch housing bolt holes with the engine flywheel housing bolt holes and install all capscrews and tighten finger tight.

Installation Requirements

3. 4.

5. 6. 7.

Note: The clutch housing must be flush against the engine flywheel housing before tightening any capscrews. Do not use the capscrews to seat housing. 8. Tighten four capscrews at 90 intervals around the clutch housing, then tighten the remaining transmission mounting capscrews using the recommended torque specifications.

Note: Do not tighten any mounting capscrews until all capscrews have been installed and finger tightened. Do not remove the transmission support chain or jack until all mounting bolts have been tightened.

16

Installation Requirements

Using Rear Supports

The OEM is responsible for determining if rear transmission support is required. 1. 2. 3. The transmission nodal mounting pads are approved to be used as a rear engine support location. The OEM is responsible for nodal mount design. Torque transmission nodal mount capscrews (3/4-10 UNC) to 180-190 lbs. ft. [224-258 Nm] of torque

Typical Rear Support Designs

17

Electrical Requirements

Top 2 Valve Electrical Requirements

Mating connector description:

Electrical Requirements

Designation

Description Connector Body

Part Number 12110293 12048086 12048074 12052845

Quantity 1 3 3 1

J1

Cable Seal Terminal Secondary

18

Electrical Requirements

Wiring Diagram OEM Responsibility

Caterpillar Programming
Note: All information on this page is only for a Caterpillar engine.

End-of-Line Programming at the OEM

Caterpillar units will already be programmed with all known features. The features simply need to be enabled. The VEPS software allows the OEM to activate / deactivate features.

Programming at the Distributor Site

Contact your Caterpillar representative for programming instructions. Service Tool ET (Electronic Technician) allows for the activation of the Eaton Top 2 Transmission Style parameter. Once the Eaton Top 2 is activated, gear ratios must be programmed as well. Each ratio must be programmed to three decimal places. Those ratios are as follows:

Transmission Model RTLO-XX610B-T2 RTL-XX710B-T2 RTL-XX910B-T2 RTLO-XX713A-T2 RTLO-XX913A-T2 RTLO-XX718B-T2 RTLO-XX918B-T2 RTLOC-1X909A-T2

Top Gear Minus Two Ratio 1.352 1.825 1.000 1.000 1.000

Top Gear Minus One Ratio 1.000 1.351 0.856 0.856 0.856

Top Gear Ratio 0.741 1.000 0.730 0.730 0.730

Note: XX appearing in the transmission model number refers to the XX x 100 = Nominal Torque Capacity. For example, RTLO-14610B-T2 has a nominal torque capacity of 14 x 100 or 1400 lbs. ft. Multi-function Output #7 is programmed as the Shift Solenoid in the Output Selections Group. Multi-function Output #6 is programmed as the Lockout Solenoid in the Output Selections Group. Caterpillar recommends locking out all Eaton Top 2 related parameters after programming has been completed and proper operation has been verified. Note: After parameters have been locked out, Factory Passwords are required to edit.

19

Electrical Requirements

Caterpillar Schematic Diagram

19

20

Interconnection Table
From Top 2 Solenoid Valve A B C To Engine Control Module Connector (P1) 19 none 20 Description Lockout

Electrical Requirements

Engine Ground Stud Shift

Caterpillar Wiring Diagram

20

Electrical Requirements

Detroit Diesel Programming

Note: All information on this page is only for a Detroit Diesel engine.

End-of-Line Programming at the OEM

DDEC units will already be programmed with all known features. The features simply need to be enabled. The VEPS software allows the OEM to activate / deactivate features or configure individual ECM pins. VEPS can assign any ECM pin to a specific function, as long as the physical function of the pin is compatible. Usually this is automatic with VEPS software, but can be assigned manually as well. This method is used after order entry when the required features are known.

Programming at the Distributor Site

DDEC units are programmed with all features and are setup in a similar fashion to the End-of-Line Programming. The distributor programming station will download the latest software version from the DDC mainframe. The distributor will trace back the wires from the Top 2 solenoids and manually enter in the individual pin numbers as assigned to the Top 2 Lock-Out Solenoid and the Top 2 Shift Solenoid drivers which then activates the Top 2 feature. For further information, contact your Detroit Diesel representative. Programming Information:

DDEC III and IV

Circuit Name Auxiliary Output #1 Auxiliary Output #2 Auxiliary Output #5 Auxiliary Output #6 Auxiliary Output #7 Auxiliary Output #8 SID 26 40 53 54 55 56 Pin F-3 A-2 W-3 X-3 Y-3 A-1 Connection OEM Vehicle Interface Connector OEM Vehicle Interface Connector Top 2 3-Way Connector Top 2 3-Way Connector Top 2 3-Way Connector OEM Vehicle Interface Connector

Diagnostic tools can verify the configuration of the solenoids with functional identifiers that are noted below. The Lockout solenoid is given a functional identifier of 31. The Shift solenoid is given a functional identifier of 30. While Eaton recommends the use of Auxiliary Output 5 (W-3) as Lockout and the use of Auxiliary Output 7 (Y-3) as Shift, any two of the above outputs can be used.

DDEC V
Circuit Name Digital Output Digital Output SID 40 53 Pin V-5 V-6 Connection Top 2 3-Way Connector Top 2 3-Way Connector

21

Electrical Requirements

DDEC III and IV Schematic Diagram

Electrical Requirements

Select two of the available six Auxiliary Outputs for use as Lockout and Shift. These two selected pins must be noted and used during the programming of the ECM.

22

Electrical Requirements

DDEC V Schematic Diagram

Dig Output (V-5) Dig Output (V-6)

23

Electrical Requirements

DDEC III, IV and V Wiring Diagram

Electrical Requirements

Typical DDEC III and IV System Overview

Top 2 Valve

ECM DDEC III & IV

Vehicle Interface Connector

24

Electrical Requirements

Typical DDEC V System Overview

Top 2 Valve

ECM DDEC V

DDEC III and IV ECM Harness Connector

Pins available for selection through engine sensor pigtail harness: W-3, X-3, and Y-3. Note: Any two of the six pins listed may be used for Lockout and Shift. After deciding which two pins will be used, refer to the End-of-Line Programming information based on your engine type, to complete the programming of the ECM.

DDEC V ECM Harness Connector

46 31 65 68 64 40 56 55 45 61 60 41

16

26 11

25

10

DDEC III and IV OEM Vehicle Interface Connector

30 15

Pins available for selection: A-1, A-2, and F-3.

25

Line Inspection

Line Inspection and Road Test Instructions

Refer to the Line Inspection Form while performing the following procedure: 1. Power Supply Checks: 2. DDEC - Visually verify the power connections at the battery bus through a 10 amp circuit breaker or fuse. Caterpillar - Visually verify the ground connection between the solenoids and truck. Cummins - Visually verify the ground connection between the solenoids and truck.

Oil Fill: Verify the transmission has been filled with the correct amount of oil and type before starting engine. Failure to add sufficient oil could damage the transmission. Use Eaton Roadranger CD50 or equivalent as specified in TCMT-0021 the Roadranger Product Lubrication Manual on the www.Roadranger.com Literature Center.

3.

End-of-line Programming

Line Inspection

See page 19, page 21, page 29, or page 31 depending on your engine type.

Dyno / Road Test 4. 5. 6. 7. 8. 9. Verify correct clutch adjustment and correct pedal free travel per clutch manufacturers requirements. Verify through normal operation that all transmission forward and reverse gears can be obtained. Verify transmission makes automatic shifts in lever position AUTO. Visually check for oil drips or residue on the transmission and related cooler lines, if used. Make sure that the correct transmission dash label is present and that the drivers instruction booklet is included with the other vehicle information. Verify that a label to alert the customer of type and brand of oil used in the transmission is attached tot the transmission or included with other vehicle information. Clear fault codes in the engine ECM. Refer to OEM engine literature.

26

Line Inspection

Line Inspection Form

Inspection Sheet

TOP 2 Line Inspection

Oem Chassis S/N Trans Model # Trans S/N

Description

Yes

No

Corrected

Pre-Start Checks
1. 2. 4. 5. Power Supply check: Oil Fill - Eaton Roadranger

DYNO/ROAD TEST CHECKS Correct clutch free travel and adjustment All forward and reverse gears obtained (Including Automatic Shifting Gears) 6. Verify no transmission oil leaks 7. Verify Top 2 shift label Drivers Instructions book in cab 8. Oil type & brand affixed to vehicle 9. Clear Fault Codes in Engine ECM Comments
Final Inspection Date Signature
Please send copy to: Eaton Corp. FAX #(269) 383-5520 ATTN: Automation Installations Group or mail copy to : Eaton Corp, 13100 E. Michigan Ave., Galesburg, MI 49053 ATTN: Automation Installations Group

27

Line Inspection

Troubleshooting
Check for proper air pressure. See Pneumatic Air Diagrams.

Check for proper lube level. See Lubrication Requirements.

Check transmission power circuits. See Schematic Diagrams for fuse and ground information.

Line Inspection

Functional? YES

Resume operation.

NO

When Shift Lever is in the "AUTO" position, the transmission does not make any automatic shifts. Manual splitter shifts are normal.

The Splitter Button does not work, however, the transmission does make shifts in the "AUTO" position.

The Splitter Button does not work and the transmission does not make automatic shifts in the "AUTO" position.

When Shift Lever is in the "AUTO" position, the transmission does not make any automatic shifts. Manual splitter shifts are normal.

The Splitter Button does not work, however, the transmission does make shifts in the "AUTO" position.

The Splitter Button does not work and the transmission does not make automatic shifts in the "AUTO" position.

Call the Roadranger Call Center at 1-800-826-HELP (4357).

Functional? NO YES

Resume operation.

28

45.5mA MAX

29
TO +BATTERY TO VEHICLE COMPONENTS CHECK ENGINE LAMP L994-YL 0.3A CURRENT LIMIT WARNING LAMP 659-PK 0.3A CURRENT LIMIT P2 J2 NOTE B SIGNAL+ SIGNALC973-GN C974-PU L994-YL 659-PK K998-BU G880-PK J906-BR G881-BU G882-WH SPEEDOMETER NOTE E NOTE H NOTE B SIGNAL+ SIGNAL451-BR TACHOMETER NOTE E NOTE H 450-YL 451-BR L901-GY G842-GY G843-OR G844-PK 100mA 100mA 450-YL C974-PU C973-GN E718-PK E991-GY G836-WH NOTE D NOTE D +BATTERY -BATTERY SAE J1939/13 OFF-BOARD DIAGNOSTIC CONNECTOR B A J H G J1587 DLINK ATA NEGATIVE J1587 DLINK ATA POSITIVE F E J1939 DATA LINK Shield J1939 DATA LINK Negative D J1939 DATA LINK Positive C E793-BU E794-YL A249-BK K990-GN K900-YL TO CHASSIS J1939 DATA LINK 10A 10A 10A 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 101-RD 101-RD 101-RD 229-BK 229-BK 229-BK G933-YL E793-BU E794-YL A249-BK K990-GN K900-YL SET/RESUME H795-PK C978-BR 6.5mA C979-OR 6.5mA 6.5mA SERVICE BRAKE PEDAL POSITION N/C 6.5mA C992-PU COOLING FAN SOLENOID H795-PK (PEDAL RELEASED POSITION) F713-OR C978-BR C979-OR K999-GN K980-PK C975-WH K982-YL G841-GN C992-PU G837-YL G838-BR G839-BU G840-PU C977-BU RETARDER SOLENOID ON/OFF SWITCH NOTE H 13mA
LO

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

Caterpillar

N/O RELAY

OFF C ON S START R

KEY SWITCH

Wiring Diagrams

BAT MTR

ALTERNATOR

GROUND

STARTER MOTOR (12V)

- 12V+

- 12V+

- 12V+

BATTERY 3

BATTERY 2

BATTERY 1

NOTE J

C11, C13, C15, and C18 OEM Diagrams (2003)

ENGINE BLOCK

CRUISE CONTROL ON/OFF

Appendix

H795-PK

C975-WH

CLUTCH PEDAL POSITION N/C

H795-PK (PEDAL RELEASED POSITION) E716-GY ENGINE RETARDER SOLENOID SELECTOR SWITCH E717-GN
MED HI LO MED HI

C977-BU 6.5mA

H795-PK

E716-GY G879-OR C983-WH C984-YL E717-GN

A/C HIGH PRESS. SWITCH N/C

6.5mA NOTE H

H795-PK NOTE C NOTE F PASSIVE MAGNETIC VEHICLE SPEED SENSOR G808-BU G809-GN

E971-GN 1 2

E971-GN G834-PU G835-OR G808-BU G809-GN

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION 40mA 5mA

ACCELERATOR PEDAL POSITION SENSOR

BK B H795-PK RD A C985-BU WH C C986-BR J403 P403

G845-PU H795-PK C985-BU C986-BR

28 CHECK ENGINE LAMP 29 WARNING LAMP 30 OUTPUT #1 31 OUTPUT #9 70 IGNITION KEY SWITCH 62 INPUT #12 64 INPUT #13 61 36 SPEEDOMETER POSITIVE 37 SPEEDOMETER NEGATIVE 10 OUTPUT #2 12 OUTPUT #3 13 OUTPUT #4 15 16 38 TACHOMETER POSITIVE 39 TACHOMETER NEGATIVE 18 INPUT SENSOR COMMON #1 47 INPUT #5 (NOTE L) 6 INPUT #6 (NOTE L) 46 INPUT #7 (NOTE L) 57 27 INPUT #9 J1587 DATA LINK NEGATIVE 9 J1587 DATA LINK POSITIVE 8 42 J1939 DATA LINK SHIELD (NOTE K & NOTE M) 34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M) 50 J1939 DATA LINK POSITIVE (NOTE K & NOTE M) 1 14 26 INPUT #10 48 UNSWITCHED +BATTERY (NOTE D) 52 UNSWITCHED +BATTERY (NOTE D) 53 UNSWITCHED +BATTERY (NOTE D) 63 -BATTERY 65 -BATTERY 67 -BATTERY 3 INPUT SENSOR COMMON #2 17 INPUT #14 C453-YL 35 SET 44 RESUME 993-BR 56 INPUT #1 (NOTE L) 58 INPUT #2 (NOTE L) 59 CRUISE CONTROL ON/OFF SWITCH 60 INPUT #3 (NOTE L) 7 INPUT #4 (NOTE L) 45 SERVICE BRAKE PEDAL POSITION SWITCH 11 OUTPUT #5 19 OUTPUT #6 20 OUTPUT #7 21 OUTPUT #8 22 CLUTCH PEDAL POSITION SWITCH 43 23 RETARDER SOLENOID LOW/HI SWITCH 2 +5V 49 ENGINE COOLANT LEVEL NORMAL (NOTE G) 54 ENGINE COOLANT LEVEL LOW (NOTE G) 40 RETARDER SOLENOID MED/HI SWITCH 51 55 41 INPUT #11 (NOTE L) 24 INPUT #15 POSITIVE 25 INPUT #15 NEGATIVE 32 VEHICLE SPEED IN POSITIVE (NOTE F) 33 VEHICLE SPEED IN NEGATIVE 69 68 INPUT #8 (NOTE L) 5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMO 4 +8V 66 ACCELERATOR PEDAL POSITION P1 J1

VEHICLE HARNESS CONNECTOR

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS DO NOT CONNECT TO GROUND OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37, J1-38, AND J1-39 IS +/10 VOLTS. AMPLITUDE WILL BE +/- 5 VOLTS NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED OR GREATER IF LOAD CURRENT IS LESS THAN 4mA.

NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS

NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION TO THE BATTERY IS NOT REQUIRE

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS TO +BATTERY

N/O RELAY TO VEHICLE COMPONENTS CHECK ENGINE LAMP L994-YL 0.3A CURRENT LIMIT WARNING LAMP 659-PK 0.3A CURRENT LIMIT P2 J2

OFF C ON S START R NOTE B SIGNAL+ SIGNALC973-GN C974-PU L994-YL 659-PK K998-BU G880-PK J906-BR G881-BU G882-WH CHECK ENGINE LAMP WARNING LAMP OUTPUT #1 OUTPUT #9 IGNITION KEY SWITCH INPUT #12 INPUT #13

KEY SWITCH SPEEDOMETER NOTE E NOTE H NOTE B SIGNAL+ SIGNAL451-BR TACHOMETER NOTE E NOTE H 450-YL 451-BR L901-GY G842-GY G843-OR G844-PK 100mA 100mA 450-YL C974-PU C973-GN E718-PK E991-GY G836-WH SPEEDOMETER POSITIVE SPEEDOMETER NEGATIVE OUTPUT #2 OUTPUT #3 OUTPUT #4

BAT MTR

ALTERNATOR

C15 OEM Diagrams (2004)

GROUND SAE J1939/13 OFF-BOARD DIAGNOSTIC CONNECTOR +BATTERY -BATTERY

STARTER MOTOR (12V)

NOTE D NOTE D

TACHOMETER POSITIVE TACHOMETER NEGATIVE INPUT SENSOR COMMON #1 INPUT #5 (NOTE L) INPUT #6 (NOTE L) INPUT #7 (NOTE L)

- 12V+

- 12V+

- 12V+

BATTERY 3

BATTERY 2

BATTERY 1

NOTE J TO CHASSIS J1939 DATA LINK 10A 10A 10A 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 101-RD 101-RD 101-RD 229-BK 229-BK 229-BK

B A J H J1587 DATA LINK NEGATIVE G J1587 DATA LINK POSITIVE F E J1939 DATA LINK Shield D J1939 DATA LINK Negative J1939 DATA LINK Positive C E793-BU E794-YL A249-BK K990-GN K900-YL G933-YL E793-BU E794-YL A249-BK K990-GN K900-YL INPUT #9 J1587 DATA LINK J1587 DATA LINK J1939 DATA LINK J1939 DATA LINK J1939 DATA LINK

NEGATIVE POSITIVE SHIELD (NOTE K & NOTE M) NEGATIVE (NOTE K & NOTE M) POSITIVE (NOTE K & NOTE M)

ENGINE BLOCK

SET/RESUME H795-PK C978-BR 6.5mA C979-OR 6.5mA

Appendix

CRUISE CONTROL ON/OFF C975-WH 6.5mA SERVICE BRAKE PEDAL POSITION N/C H795-PK C992-PU 6.5mA (PEDAL RELEASED POSITION) COOLING FAN SOLENOID

H795-PK

45.5mA MAX

CLUTCH PEDAL POSITION N/C C977-BU 6.5mA H795-PK RETARDER SOLENOID ON/OFF SWITCH NOTE H 13mA

H795-PK (PEDAL RELEASED POSITION)

F713-OR C978-BR C979-OR K999-GN K980-PK C975-WH K982-YL G841-GN C992-PU G837-YL G838-BR G839-BU G840-PU C977-BU E716-GY G879-OR C983-WH C984-YL E717-GN

INPUT #10 UNSWITCHED +BATTERY (NOTE D) UNSWITCHED +BATTERY (NOTE D) UNSWITCHED +BATTERY (NOTE D) -BATTERY -BATTERY -BATTERY INPUT SENSOR COMMON #2 INPUT #14 C453-YL SET RESUME 993-BR INPUT #1 (NOTE L) INPUT #2 (NOTE L) CRUISE CONTROL ON/OFF SWITCH INPUT #3 (NOTE L) INPUT #4 (NOTE L) SERVICE BRAKE PEDAL POSITION SWITCH OUTPUT #5 OUTPUT #6 OUTPUT #7 OUTPUT #8 CLUTCH PEDAL POSITION SWITCH RETARDER SOLENOID LOW/HI SWITCH +5V ENGINE COOLANT LEVEL NORMAL (NOTE G) ENGINE COOLANT LEVEL LOW (NOTE G) RETARDER SOLENOID MED/HI SWITCH

A/C HIGH PRESS. SWITCH N/C E971-GN NOTE C NOTE F PASSIVE MAGNETIC VEHICLE SPEED SENSOR G808-BU G809-GN 1 2 E971-GN G834-PU G835-OR G808-BU G809-GN

6.5mA NOTE H

H795-PK

INPUT #11 (NOTE L) INPUT #15 POSITIVE INPUT #15 NEGATIVE VEHICLE SPEED IN POSITIVE (NOTE F) VEHICLE SPEED IN NEGATIVE

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION 40mA 5mA

ACCELERATOR PEDAL POSITION SENSOR

B BK H795-PK A RD C985-BU C WH C986-BR J403 P403

G845-PU H795-PK C985-BU C986-BR

28 29 30 31 70 62 64 61 36 37 10 12 13 15 16 38 39 18 47 6 46 57 27 9 8 42 34 50 1 14 26 48 52 53 63 65 67 3 17 35 44 56 58 59 60 7 45 11 19 20 21 22 43 23 2 49 54 40 51 55 41 24 25 32 33 69 68 5 4 66 INPUT #8 (NOTE L) ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8V ACCELERATOR PEDAL POSITION P1 J1

VEHICLE HARNESS CONNECTOR

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, DO NOT CONNECT TO GROUND

NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS

NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED

NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37, J1-38, AND J1-39 IS +/- 10 VOLTS. AMPLITUDE WILL BE +/- 5 VOLTS OR GREATER IF LOAD CURRENT IS LESS THAN 4mA.

NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION TO THE BATTERY IS NOT REQUIRED

Appendix

30

30 WAY CONNECTOR DDC P/N: 12034398 TERMINAL DDC P/N: 12103881 PLUG DDC P/N: 12034413
OI T-STAT DIGITAL INPUT* 953 BLK/WHT
B A

31

Detroit Diesel

SERIES 60 DDEC IV MY2003 EGR VEHICLE INTERFACE HARNESS

OEM RESPONSIBILITY
IGNITION CRUISE CONTROL
WIRE NO. COLOR DASH PANEL GN DIGITAL OUTPUT* ON OFF ON OFF ON OFF +12/24 953 DEDICATED 12/24 VDC BATTERY POWER MUST BE SOURCED DIRECTLY FROM BATTERY POST OR BUS BAR
1 2 3

LABEL CAVITY COLOR

WIRE NO

GOVERNOR
WIRE NO COLOR 916 RED/BLK C 417 DK BLUE B 952 BLK A LIMITING SPEED GOVERNOR (THROTTLE POSITION SENSOR) DIGITAL INPUT* DIGITAL INPUT* DIGITAL INPUT* SET/COAST SWITCH RESUME/ACCE SWITCH CRUISE ENABLE SWITCH

BLK/WHT

440
A B

115 417 419 439 451 499 505 509 510 ORN DK BLUE PPL/WHT PNK LT GRN LT BLU GRA PPL BRN
ORN SWITCHED IGNITION
OFF ON + 12/24 VDC

H-3 D-2 B-1 B-3 E-1 F-3 K-1 B-2 D-1

WIRE NO COLOR 439 PNK VARIABLE SPEED GOVERNOR (POWER TAKE-OFF CONTROL)
- OR -

916 RED/BLK 510 BRN 952 BLK C B A

DDEC IV Vehicle Interface Harness

F G H J K

DIGITAL INPUT* BRAKE SWITCH CLUTCH SWITCH OFF

ON ON OFF

MUST PROVIDE IGNITION POWER IN RUN AND CRANK MODES. DO NOT SOURCE ANY ACCESSORY FROM CIRCUIT 439 510 BRN

VEHICLE SPEED SENSOR 556 557 LT LT BLU/ORN RETURN CONNECTOR DDC P/N 12015378 TERMINAL DDC P/N 12089188 SIGNAL

523 524 528 531 541 542 543 544 545 555 556 557 583 749
NOTE: FUSE MUST BE PLACED BETWEEN MATING CONNECTOR AND BATTERY

H-1 H-2 G-1 J-2 J-1 F-1 G-2 F-2 G-3 A-2 E-2 E-3 K-2 D-3

GRA/RED GRA BRN/RED ORN YEL/RED YEL ORN/BLK BRN/WHT LT BLUE/YEL TAN LT BLUE/BLK LT BLUE/ORN LT BLUE/BLK YEL

900 901 908 * DIGITAL INPUTS AND DIGITAL OUTPUTS ARE PROGRAMMABLE BY THE OEM

C-2 C-1 J-3

DK GREEN/YEL DK GREEN WHT

INSTRUMENT PANEL
6-PIN CONNECTOR
WIRE NO. CAVITY LABEL COLOR

DIAGNOSTIC CONNECTOR

OEM CONNECTION TO ESH

WIRE NO COLOR 1 1 2
DDD-XX XXXXX

COOLANT LEVEL LIMITING SPEED GOVERNOR CHECK ENGINE LIGHT IGNITION DIGITAL INPUT E-1 DIGITAL OUTPUT F-3 TACHOMETER DRIVE STOP ENGINE LIGHT OI THERMOSTAT OR PTO OR EXHAUST BACK PRESSURE (COACH ONLY) DIGITAL INPUT H-1 DIGITAL INPUT H-2 DIGITAL INPUT G-1 DIGITAL INPUT J-2 DIGITAL INPUT J-1 DIGITAL INPUT F-1 DIGITAL INPUT G-2 DIGITAL INPUT F-2 DIGITAL INPUT G-3 DIGITAL OUTPUT A-2 VEHICLE SPEED (+) VEHICLE SPEED (-) DIGITAL INPUT K-2 ESS TRANS OR FIRE TRUCK PUMP PRESSURE OR EXHAUST TEMP DATA LINK (+) DATA LINK (-) PWM FAN OR OI ALARM OR PWM TRANSMISSION SENSOR SUPPLY (5VDC) SENSOR RETURN DIGITAL INPUT K-3 DIGITAL OUTPUT A-1 A-3 C-3 K-3 A-1
WIRE NO. COLOR

916 952 979 988 A B ORN BLK/WHT

419 PPL/WHT
CONNECTOR DDC P/N: 23513052 COVER DDC P/N: 23513054 TERMINAL DDC P/N: 23513053

RED/BLK BLK WHT GRA

509 PPL STOP ENGINE LIGHT RED RD
900 901 440 --953 --A B C D E F DATA LINK (+) DATA LINK (-) + 12/24 VDC PLUG P/N: 23507136 BATTERY GROUND PLUG P/N: 23507136 DK GRN/YEL TWISTED DK GRN RED --BLK/WHT ---

IGNITION CONNECTOR

+12 V FROM BATTERY BATTERY GROUND

CHECK ENGINE LIGHT YELLOW YE

440 953

953 439 452 976 3 4 416 910 905

2 3 4 5 6 7 TO OI STARTER RELAY 565 564 TO VEHICLE DIGITAL OUTPUT WIRING 563 RED TAN/BLK YEL 8 9 10

GND (VPOD GND) IGN (VPOD POWER) SENSOR RETURN RELATIVE HUMIDITY SENSOR SUPPLY OI STARTER TURBO COMP INLET

Appendix

COOLANT LEVEL SENSOR

+12/24VDC

BLK PNK BLK WHT GRA ORN YEL

- OR 9-PIN CONNECTOR
WIRE NO. CAVITY COLOR LABEL

RELATIVE HUMIDITY/ TCI SENSOR CONNECTOR FC/APEX P/N: 54200409 TERMINAL (GOLD) P/N: JTP-1811-66AU

WIRE NO. CAVITY 115 A 953 B

COLOR ORN BLK/WHT

DIGITAL OUTPUT Y-3 DIGITAL OUTPUT X-3 DIGITAL OUTPUT W-3

CONNECTOR (10-PIN) APEX P/N: 54201016 TERMINAL APEX P/N: LSP-1811-58AU

(+) BATTERY POSITIVE (-) BATTERY NEGATIVE

12 OR 24 VDC SUPPLY

POWER HARNESS SINGLE ECM SINGLE FUSE

CRIMP WIRES INTO SINGLE CONNECTOR AT BATTERY ONLY

953 440 925 926 927 900 901 ----A B C D E F G H J BLK/WHT RED DK BLU DK BLU/WHT WHT/BLU DK GRN/YEL TWISTED DK GRN -----

BATTERY GROUND +12/24V J1939 DATA LINK (+) J1939 DATA LINK (-) J1939 SHIELD DATA LINK (+) DATA LINK (-) PLUG P/N: 23507136 PLUG P/N: 23507136

CONNECTOR DDC P/N: 23529496 COVER DDC P/N: 23529497 TERMINAL DDC P/N: 23507132
WIRE NO. DIGITAL INPUT* 953 BLK/WHT N.O. COLOR DIAGNOSITC REQUEST AND STOP ENGINE OVERRIDE SWITCH

COOLANT LEVEL PROBE 3/8 in. NPT DDC P/N: 23520381 1/4 in. NPT DDC P/N: 23520380 9/16 in. UNF DDC P/N: 23522855
COLOR-RED (2) CABLES REQ'D. COLORBLACK (4) CABLES REQ'D. ECM POWER CONNECTOR * FUSE IGNITION FUSE C 241 150 150 150 240 USE 12 AWG WIRE NOT TO EXCEED 14 FEET IN LENGTH. A 440 953 B E B B D A A C CONNECTOR P/N: 12124634 TERMINAL P/N: 12077413 CABLE SEAL P/N: 12015193 SECONDARY LOCK WIRE P/N: 12052816 CAVITY NO.

280 SERIES METRI-PACK CONNECTOR DDC P/N: 15300027 TERMINAL DDC P/N: 12077411 CABLE SEAL DDC P/N: 12015323 SECONDARY LOCK DDEC P/N: 15300014
E C B D A

COMMUNICATION CONNECTOR CAVITY F E D C B A

WIRE NO. 925 926 927 439 801 800

WIRE COLOR DK BLU DK BLU/WHT WHT/BLU PNK TAN TAN/WHT

LABEL CAN_H/J 1939 (+) CONTROL DATA LINK CAN_L/J 1939 (-) CONTROL DATA LINK CAN_SHLD/J 1939 SHIELD IGNITION (OPTIONAL) J 1922 (-) DATA LINK J 1922 (+) DATA LINK

COMMUNICATION HARNESS
COMMUNICATIONS CONNECTOR P/N: 12066317 TERMINAL P/N: 12103881 PLUG P/N: 12034413

IGNITION CONNECTOR

CONNECTOR P/N: 12034074 TERMINAL P/N: 12089040

NOTE: * FUSES OR CIRCUIT BREAKERS ARE TO BE LOCATED AS CLOSE TO THE BATTERY AS PRACTICAL AND MUST BE HOUSED WITHIN WEATHERPROOF HOLDER. USE WATERPROOF SPLICES TO SPLICE 12 GA. WIRES TO APPROPRIATE WIRE GAUGE CABLES FROM BATTERY POWER.

All information subject to change without notice. (Rev. 8/03) 7SA743 0308 Copyright 2003 DETROIT DIESEL CORPORATION.

42893

LABEL
16

CAVITY
POWER WIRING
SPARE DIGITAL & PWM OUTPUTS/INPUTS
CAVITY
V-5 LOW SIDE DIGITAL OUTPUT

46
GOVERNOR THROTTLE PEDAL
CAVITY V-11
V-6 LOW SIDE DIGITAL OUTPUT

CRUISE CONTROL
CAVITY DASH PANEL +12/24V DIGITAL OUTPUT C B A V-8 V-9 RESUME/ACCEL SWITCH SET/COAST SWITCH SERVICE BRAKE SWITCH OFF CLUTCH SWITCH ON OFF SENSOR RETURN #2 VEHICLE SPEED SENSOR V-17 SIGNAL V-18 RETURN CRUISE ENABLE SWITCH

31
CAVITY LABEL LABEL SENSOR SUPPLY #1 ALSG SENSOR RETURN #1 V-61 V-62 V-65 V-13
V-52 PWM OUTPUT PWM OUTPUT

1
LABEL BATTERY (+) BATTERY (+) BATTERY (+) BATTERY (+) V-60 BATTERY (-) BATTERY (-) V-16 IDLE VALIDATION SENSOR RETURN #2 V-3 V-11 C V-10 V-59 B A V-14 V-60
V-26 V-11 SENSOR SUPPLY #1* INPUT V-46

30 AMP BATTERY (+)

25
V-66 V-63 V-64 V-67 V-68 IGNITION FUSE
V-11 SENSOR SUPPLY #1*

OFF ON ON OFF OFF ON

55 10
BATTERY (-) BATTERY (-) INPUT WITH 1.5k PULL-UP SENSOR SUPPLY #1 VSG SENSOR RETURN #1
V-48 INPUT

AUTOMOTIVE LIMITING SPEED GOVERNOR

40
BATTERY (-) V-59 V-47

56
SWITCHED IGNITION
V-60 SENSOR RETURN #1

41 30 15
V-15

26 11

IDLE VALIDATION (REQUIRED)

ON

60 61 64
INPUT WITH 1.5k PULL-UP MUST PROVIDE IGNITION POWER IN RUN AND CRANK MODES. DO NOT SOURCE ANY NON-DDEC ACCESSORY FROM IGN CIRCUIT (V-15)

45

VARIABLE SPEED GOVERNOR (OPTIONAL)

65

DDEC V Vehicle Interface Harness

68
18 AWG TERMINAL DDC P/N: 23528271
V-60 * NOT USED FOR DIGITAL INPUTS RESISTORS ARE INTERNAL TO ECU SENSOR RETURN #1

68-WAY CONNECTOR DDC P/N: 23528252 14 AWG TERMINAL DDC P/N: 23528272

SHROUD SIDE OF CONNECTOR

TURBO COMPRESSOR IN TEMP

CAVITY CAVITY LABEL RED STOP LAMP V-02 RSL V-27 TCI LABEL

V-1 V-2 V-3 V-4 V-5 V-6 V-7 V-8 V-9 V-10 V-11 V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 V-22 V-23 V-24 V-25 V-26 V-27 V-28 V-29 INSTRUMENT PANEL
CAVITY

OPTIMIZED IDLE (OPTIONAL)

2 1
AMBER WARNING LAMP AWL

LABEL

V-59 SENSOR RETURN #2

TURBO COMPRESSOR IN TEMP IGN

V-55

OI ACTIVE LAMP

+12/24V

ENGINE COOLANT LEVEL SENSOR - SHUTDOWN

V-01

IGN

V-54

OI STARTER

+12/24V V-40 OI ALARM

CAVITY V-38 COOLANT LEVEL V-31 TACH OUTPUT

LABEL

A B ENGINE BRAKE SWITCHES

V-39 ENG. BRAKE LOW

+12/24V (REFER TO OPTIMIZED IDLE FOR RELAY REQUIREMENTS)

V-60 SENSOR RETURN

COOLANT LEVEL SENSOR SHUTDOWN

V-42

OI THERMOSTAT

Appendix

MAINTENANCE ALERT SYSTEM ONLY

V-51 V-59 SENSOR RETURN ENG. BRAKE MED CAVITY LABEL ADD COOLANT LEVEL V-37

TO PIN D OF THERMOSTAT CONNECTOR

A B
V-24 DIAG REQ/SEO

V-60

SENSOR RETURN

ADD COOLANT LEVEL

DIAGNOSTIC REQUEST / STOP ENGINE OVERRIDE DIAGNOSTIC CONNECTOR

CAVITY DDC CONNECTOR LABEL

V-11

SENSOR SUPPLY #1

A
V-59 SENSOR RETURN

DIAGNOSTIC REQ/ SEO SWITCH

V-22 AIR FILTER RESTRICTION

B C
V-25

AIR FILTER RESTRICTION

V-60

SENSOR RETURN #1

FAN CONTROL - SINGLE SPEED FAN

A/C STATUS FAN CTRL OVERRIDE SENSOR RETURN FAN CONTROL #1

V-60

SENSOR RETURN #1

A
V-59 V-4

V-49

V-43 V-58 V-44 V-56 V-57 -

A B C D E F G H J

GND +12/24 V J 1939 DATA LINK (+) J 1939 DATA LINK (-) J 1939 SHIELD J 1587 DATA LINK (+) J 1587 DATA LINK (-) PLUG PLUG

V-11 SENSOR SUPPLY #1

B C

FIRE TRUCK PUMP PRESSURE

V-29 PUMP PRESSURE

+12/24V

CONNECTOR DEUTSCH P/N: HD10-9-1939P DDC P/N: 23529496

CAVITY PLUG DEUTSCH P/N: 114017 DDC P/N: 23507136

PARKING BRAKE & VEHICLE POWER SHUTDOWN COACH APPLICATIONS ONLY

V-60 SENSOR RETURN #1 V-50 PARK BRAKE V-59 SENSOR RETURN

TERMINAL DEUTSCH P/N: 0460-202-16141 DDC P/N: 23507132

CONNECTOR COVER DEUTSCH P/N: HDC16-9 DDC P/N: 23529497

1 2 3 A B
EXHAUST BACK PRESSURE

V-29 EXHAUST BACK PRESSURE SENSOR SUPPLY #1 V-11

AMBER WARNING LAMP RED STOP LAMP SERVICE BRAKE RELEASED FAN CONTROL #1 DIGITAL OUTPUT DIGITAL OUTPUT VEHICLE PWR SHUTDOWN RESUME/ACCEL CRUISE ENABLE CLUTCH RELEASED SENSOR SUPPLY #1 SENSOR SUPPLY #2 THROTTLE POSITION VSG IGNITION IDLE VALIDATION VEHICLE SPEED SENSOR (+) VEHICLE SPEED SENSOR (-) NO CONNECTION NO CONNECTION NO CONNECTION AIR FILTER RESTRICTION EXHAUST TEMPERATURE SEO/DIAG REQUEST A/C STATUS ANALOG INPUT - 1.5k PULLUP TURBO COMPRESSOR IN TEMP NO CONNECTION EXHAUST BACK PRESSURE OR FIRE TRUCK PUMP PRESSURE NO CONNECTION TACHOMETER FREQUENCY - SPARE FREQUENCY - SPARE NO CONNECTION NO CONNECTION NO CONNECTION ADD COOLANT LEVEL COOLANT LEVEL - SHUTDOWN ENGINE BRAKE LOW OI ALARM AUX SHUTDOWN #1 OI THERMOSTAT J 1939 DL (+) J 1939 DL SHIELD NO CONNECTION PWM OUTPUT SET/COAST ANALOG INPUT - 1.5k PULLUP FAN CONTROL OVERRIDE PARK BRAKE ENG BRAKE MED PWM OUTPUT ETHER START OI STARTER OI ACTIVE LAMP J 1587 + J 1587J 1939 DL (-) SENSOR RETURN #2 SENSOR RETURN #1 +12V / +24V +12V / +24V BATTERY GROUND BATTERY GROUND +12V / +24V +12V / +24V BATTERY GROUND BATTERY GROUND
V-7 VEHICLE POWER SHUTDOWN

V-30 V-31 V-32 V-33 V-34 V-35 V-36 V-37 V-38 V-39 V-40 V-41 V-42 V-43 V-44 V-45 V-46 V-47 V-48 V-49 V-50 V-51 V-52 V-53 V-54 V-55 V-56 V-57 V-58 V-59 V-60 V-61 V-62 V-63 V-64 V-65 V-66 V-67 V-68
IGN
V-60 V-23 EXHAUST TEMPERATURE SENSOR RETURN #1

All information subject to change without notice. (Rev. 6/05) 7SA821 0506 Copyright 2005 DETROIT DIESEL CORPORATION

EXHAUST TEMPERATURE

DDEC V VEHICLE INTERFACE HARNESS

40106

Appendix

32

Appendix

Torque Specifications
Part Flywheel capscrews Transmission-to-Engine capscrews 7/16-14 * 3/8-16 * M10 x 1-3/8 * M10 x 1-3/4 * Output yoke nut PTO mounting capscrews: 6-bolt opening * 8-bolt opening * Reverse switch (9/16-18) Neutral switch/cap (3/4-16) Speedometer electronic sensor (3/4-16) Lubricant fill plug (1-NPT) Lubricant drain plug (3/4-NPT) Lifting bracket capscrew (3/8-16) Rear bearing cover capscrew (3/8-16) Transmission nodal mount capscrews (3/4-10) Transmission rear support stud nuts (5/8-18) Range Air Valve Mounting Screw (#10-24) 20 - 25 lbs. ft. [27 - 34 Nm] 50 - 65 lbs. ft. [68 - 88 Nm] 20 - 25 lbs. ft. [27 - 34 Nm] 20 - 25 lbs. ft. [27 - 34 Nm] 10 - 15 lbs. ft. [14 - 20 Nm] 60 - 75 lbs. ft. [81 - 101 Nm] 45 - 55 lbs. ft. [61 - 75 Nm] 35 - 45 lbs. ft. [47 - 61 Nm] 35 - 45 lbs. ft. [47 - 61 Nm] 180 - 190 lbs. ft. [244 - 258 Nm] 170 - 185 lbs. ft. [230 - 250 Nm] 21 - 27 lbs. in. [2 - 3 Nm] 37 - 50 lbs. ft. [50 - 68 Nm] 25 - 32 lbs. ft. [34 - 43 Nm] 26 - 35 lbs. ft. [35 - 47 Nm] 26 - 35 lbs. ft. [35 - 47 Nm] 450 - 500 lbs. ft. [610 - 678 Nm] Torque Follow engine manufacturers specifications

* Thread adhesive sealant required.

33

Appendix

Suggested Tools
O.E. Tool & Equipment Group/Kent-Moore SPX Corporation 1-800-520-2584 Kent-Moore Part no. 5505027 Description Volt/Ohm Meter (Standard commercially available VOM)

O.E. Tool & Equipment Group/Kent-Moore SPX Corporation 1-800-328-6657 Kent-Moore Part no. J-43318 Description Eaton Test Adapter Kit MD-100

Eaton Service Parts 1-800- 826-HELP (4357) Part No. Description MD-200

Engine Tools Contact your local engine representative for the latest tools specifications.

Related Publications
Troubleshooting Guide Service Manuals TRTS-0070 TRSM-0550 - RTLO 10-speed Models TRSM-0670 - RTLO 13-speed, 18-speed, and Convertible Models Illustrated Parts Lists Driver Instructions See model specific listing TRDR-0550 - RTLO 10-speed Models TRDR-0670 - RTLO 13-speed Models TRDR-0800 - RTLO 18-speed Models TRDR-3349 - Convertible Models Lubrication Requirements TCMT-0020 - Roadranger Products Approved Lubricants TCMT-0021 - Roadranger Products Lubrication Manual For additional information call the Roadranger Call Center at 1-800-826-HELP (4357).

Appendix

34

Appendix

Application Forms

Eaton Fuller

Form FUL-169

Transmissions
Approved Applications For Fuller Twin Countershaft Mechanical and Top-2 Transmissions
Written Approval Required For All Applications Not Meeting the Requirements of This Form - Use Form FUL170 (Request for Application Approval). All approvals are based on the following conditions: Lubricants must meet the requirements published in Eaton TCMT-0021. Driveline speed not to exceed 3000 RPM except RT-6609 -4000 RPM. Angular acceleration of driveline is not to exceed 300 rad/s 2 . High Angle lubrication kit required when installation angle plus operating grade angle exceeds 12 degrees (20%). Vehicle must have sufficient overall reduction to insure Startability (See Startability Attachment FUL-171). PTO torque limit - Maximum combined PTO output torque is not to exceed 500 lbs-ft for Lightning, FR/FRO and Convertible series transmissions. All other transmissions are limited to a maximum of 350 lbs-ft with the standard input shaft bearing (P/N 82504). IF the input shaft bearing is upgraded (P/N 4301417), the PTO output torque is not to exceed 500 lbs-ft. The RT-6609 is limited to 300 lbs-ft. The maximum allowable torque at the transmission input shaft, due to engine retarding systems and engine friction, must be less than 110% of maximum transmission torque rating. Transmission input torque spikes due to drive train resonance, must be less than 300 lbs-ft above the nominal transmission input torque rating for engine speeds above 1000 RPM and vehicle road spee d above 20 MPH. Vehicle configurations that exceed the 3000 RPM driveline speed can be blanket approved IF the engine is electronically programmed to limit the vehicle speed that produces a driveline speed of 3000 RPM or less in top (overdrive) gear.
3 Max Gross H.P. 3

Max. Peak Torque

3, 4

lbs-ft
660

Transmission Series
RT-6609-A
RT-8608-L RT-8908-LL RT-8709-B FR-9210B 10XXX

GCW limit for Blanket Approval

74,000 Lbs.

Maximum Driveline Torque, "A"

9,700

NOTE 1 A calculation A1 or A2 must be less than A A1 = Peak Engine Torque x Lowest Gear Ratio A2 = 672 x W M x AR W =Weight on drive wheels Lbs. M =Tire revolution per mile AR =Axle ratio

250

860 300 950 1050 1150 370 400 450 500 1250 1350 1400 1450 1550 1650 1750 1850 2050 2250

80,000 Lbs. 12,500

Where:

All Other 11XXX RTO-11909-XLL 12XXX 13XXX T-14607 All Other 14XXX 15XXX 16XXX 17XXX
18XXX RTLO-20913/18 RTLO-22918

17,500

NOTE 2 "A" calculation for Auxiliaries

90,000 Lbs. 15,500

140,000 Lbs. 17,500

150,000 Lbs. 9,700 17,500

600 700

NOTE 3 Transmission Oil Coolers are: Recommended With engines of 350 H.P. and above. Required With engines 400 H.P. and above, and GCW s over 90,000 lbs. With engines 400 H.P. and above and 1400 lbs-ft or greater torque With engines 450 H.P. and above With engines 1500 lbs-ft and above In all cases, cooler must have sufficient capacity to maintain oil temperatures below 250F at worst case operating conditions.

NOTE 2

2-A-92 AT-1202

Additional Application Requirements for Approval of RTLOC-1X909A-T2: Application must be for On-Highway 5 use only. For engines certified by Eaton for use with Top 2 transmissions, see Form FUL-200T. Vehicle must have a minimum of 0.3% gradeability at cruise speed and 1% gradeability at peak torque. Calculations are to be made at maximum rated conditions. Vehicles using Detroit Diesel S60 engines must have rear axle ratio higher than 3.70 and tires with 492 revs/mile or greater. Vehicles using Caterpillar C11, C13 or C15 engines must have a rear axle ratio higher than 3.55 and tires with 492 revs/mile or greater. Any Progressive Shift engine programming must allow automatic up-shift points to be reached minimum 1500 RPM. Vehicle must have a 12-volt electrical system. Vehicle air system must include an air dryer.
4 5

Blanket GCW limit is just a limit for Blanket approved applications. Applications that exceed this limit need to be submitted to Eaton Corporation for approval. On-Highway is defined as limited access and general highways. Grades less than 8%, well maintained, concrete or asphalt surface, no more than 10% offhighway operation. Maintained gravel, crushed rock, hard packed dirt or similar road surfaces are acceptable when grades are less than 3%.

11/03

35

Appendix

Eaton Fuller
Transmissions Approval I.D. No.: Chassis #(s): No. of Vehicles: Projected Build Date: OEM / Plant Location: Customer/Fleet: APPROVAL REQUEST FOR:

Application Approval Form FUL-170 Rev. 01/04

Dealer Information Dealership Name: Dealer Address: / Transmission Model Model: at RPM Peak Torque RPM Top Speed Limit Setting Model: Model: Model: Model: Model: Ratios: Size: Type: Ratios: Contact: Telephone:

FAX: Oil Cooler: YES NO

ENGINE INFORMATION: Make: Rated Horsepower Governed Speed: DRIVELINE INFORMATION: Rear Axle Make: Drive Tires Make: Retarder Make: Clutch Make: Trans Case Make: /Aux. Trans

Displacement: Liters Lbs-ft at RPM MPH Cruise Speed MPH / or Revs/Mile HP /

CHASSIS INFORMATION Model: Max Weight on Drive Wheels

Drive Configuration (6x4, 4x2) Lbs Max GVW

Vehicle Voltage (12 or 24v) Lbs Max GCW

12

V Lbs

VOCATIONAL AND BODY SPECIFIC INFORMATION: Vocation (Line Haul, Dump, Refuse, Mixer, etc) Body Type Trailer Type Area of Operation: Country(s) State / Province/Region Road Usage: Highway % Secondary/City % Off-Highway Maximum Grade on Which Vehicle will be Required to Operate %

# Trailers % Off-Road %

TRANSMISSION FEATURE / OPTION REQUIREMENTS: (CHECK BOX OF APPROPRIATE CONFIGURATION) 6 Bolt Engine Split-Shaft Countershaft: 6 Bolt 8 Bolt PTO Usage: None PTO Model: PTO Driven Equipment: PERSON SUBMITTING REQUEST FIRM NAME & ADDRESS: THIS APPLICATION IS: ADDITIONAL NOTES / REQUIREMENTS: SIGNED:
1.

Aux

PHONE:

FAX:

APPLICATION ENGINEER:

DATE:
Eaton Corporation TOA P.O. Box 4013 Kalamazoo, MI 49003 Phone: (269) 342-3000 Fax: (269) 342-3574 TransApplications@Eaton.com

2. 3.

This Application Approval Form (FUL-170) is intended for use as an approval for warranty ONLY. An approval indicates that the given configuration meets the minimum requirements of the specified product; it does not indicate approval to ship the product. All Eaton warranty guidelines apply for coverage and specific labor repair times. Reference Eaton publications TCWY-0600 and TCWY-0900. Refer to form FUL-169 ( ) for Blanket Application Requirements.

Appendix

36

Copyright Eaton and Dana Corporation, 2007. EATON AND DANA CORPORA TION hereby grants its customer s, vendor s, or distributor s 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 modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

Fo r specing or service assistance, call 1-80 0-826-HELP (4357) 24 hours a day, 7 days a w eek (Mexico: 001-80 0-826-4357), for mo re time on the ro ad. O r visit our w eb sit e at www .roadr ang er.com .
Roadranger: Eaton, Dana and other trusted partner s providing the best products and services in the industry , ensuring more time on the road.
20 07 Eaton Corporation All rights reserved. Pr inted in US A

Eaton Corporation Truc k Components Operations P . O. Bo x 4013 K alamaz oo, MI 490 03 U.S.A. www .roadranger .com