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Fuller® Heavy Duty Transmissions

More time on the road ®

Installation Guide
Fuller Heavy Duty Transmissions
TRIG0070
October 2007

RTLO-11610B RTLO-16618A RTLOC-16909A-T2 RTLOF-16618A


RTLO-11610B-T2 RTLO-16713A RTLOF-11610B RTLOF-16713A
RTLO-12610B RTLO-16713A-T2 RTLOF-11610B-T2 RTLOF-16713A-T2
RTLO-12610B-T2 RTLO-16718B RTLOF-12610B RTLOF-16718B
RTLO-12713A RTLO-16913A RTLOF-12610B-T2 RTLOF-16913A
RTLO-12913A RTLO-16913A-T2 RTLOF-12713A RTLOF-16913A-T2
RTLO-13610B RTLO-16918B RTLOF-12913A RTLOF-16918B
RTLO-13610B-T2 RTLO-16918B-T2 RTLOF-13610B RTLOF-16918B-T2
RTLO-14610A RTLO-17610B RTLOF-13610B-T2 RTLOF-17610B
RTLO-14610B RTLO-17610B-T2 RTLOF-14610B RTLOF-17610B-T2
RTLO-14610B-T2 RTLO-18610B RTLOF-14610B-T2 RTLOF-18610B
RTLO-14613B RTLO-18610B-T2 RTLOF-14613B RTLOF-18718B
RTLO-14618A RTLO-18718B RTLOF-14618A RTLOF-18913A
RTLO-14713A RTLO-18718B-T2 RTLOF-14713A RTLOF-18913A-T2
RTLO-14718B RTLO-18913A RTLOF-14718B RTLOF-18918B
RTLO-14913A RTLO-18913A-T2 RTLOF-14913A RTLOF-18918B-T2
RTLO-14918B RTLO-18918B RTLOF-14918B RTLOF-20913A
RTLO-14918B-T2 RTLO-18918B-T2 RTLOF-14918B-T2 RTLOF-20918B
RTLO-15610B RTLO-20913A RTLOF-15610B RTLOF-20918B-T2
RTLO-15610B-T2 RTLO-20918B RTLOF-15610B-T2 RTLOF-22918B
RTLO-16610B RTLO-20918B-T2 RTLOF-16610B RTLOFC-16909A-T2
RTLO-16610B-T2 RTLO-22918B RTLOF-16610B-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 Failure to follow indicated
manual to call attention to procedures procedures creates a high risk of personal
where carelessness or failure to follow injury to the servicing technician.
specific instructions may result in
personal injury and/or component CAUTION
damage. Failure to follow indicated
procedures may cause component
Departure from the instructions, choice damage or malfunction.
of tools, materials and recommended
parts mentioned in this publication IMPORTANT
may jeopardize the personal safety Highly recommended procedures for
of the service technician or vehicle proper service of this unit.
operator.
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
General Information Top 2 Valve Electrical Requirements ........................ 18
Wiring Diagram OEM Responsibility ........................ 19
How to Use This Manual ............................................1
Caterpillar Programming ...................................... 19
Detroit Diesel Programming ................................. 21
Installation Requirements
Requirements .............................................................2
Space Requirements ..................................................3
Line Inspection
Line Inspection and Road Test Instructions ............. 26
10-speed Valve Location ........................................3
Line Inspection Form ............................................... 27
9- / 13-speed Valve Location ..................................5
Troubleshooting ....................................................... 28
18-speed Valve Location ........................................6
Lubrication Requirements ..........................................8
Air Supply Requirements ..........................................10 Appendix
9-speed Pneumatic Diagrams ...............................11 Wiring Diagrams ...................................................... 29
10-speed Pneumatic Diagrams .............................12 Caterpillar ............................................................. 29
13-speed Pneumatic Diagrams .............................13 Detroit Diesel ........................................................ 31
18-speed Pneumatic Diagrams .............................14 Torque Specifications .............................................. 33
Transmission Mounting Requirements ....................15 Suggested Tools ...................................................... 34
Mounting Transmission to Engine ........................16 Related Publications ................................................ 34
Using Rear Supports ............................................17 Application Forms .................................................... 35
Typical Rear Support Designs ...............................17
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 out-
lined 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.

1
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. Air Dryer Requirements - A high quality commercially available vehicle air dryer is required to be used in conjunction
with Top 2 systems.

Requirements
Installation
2. Clutch Requirements - Spring dampened clutches are required for all applications.
3. Electrical Requirements - All wires are to be a minimum of 16 gauge GXL.
4. Integral Coolers - Reference Form FUL-169 Note 2 for transmission cooler requirements.
5. 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.
6. Lubrication Requirements - Transmission oil should meet specifications as outlined in TCMT-0020 (Roadranger Prod-
ucts Approved Lubricants) and TCMT-0021 (Roadranger Products Lubrication Manual).
7. Power Connections - All ECMs will have redundant power and ground pins. If no redundancy is available, a relay con-
nection similar to the one on page 29.
8. Valve Spatial Requirements - The Top 2 solenoid valve requires a minimum of 2” clearance from any high temperature
devices (i.e. exhaust crossover pipes).

2
Installation Requirements

Space Requirements

10-speed Valve Location


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

3
Installation Requirements

Requirements
Installation
MODEL LENGTH “A” LENGTH “B” LENGTH “C”
11610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
12610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
13610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)
14610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)
15610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)
16610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)

4
Installation Requirements

9- / 13-speed Valve Location


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

5
Installation Requirements

MODEL LENGTH “A” LENGTH “B” LENGTH “C”


12713 815.1 (32.09) 200.4 (7.89) 43.9 (1.73)
14713 823.2 (32.41) 208.5 (8.21) 51.8 (2.04
16713 823.2 (32.41) 208.5 (8.21) 46.5 (1.83)
12913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

Requirements
Installation
14913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
18913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

18-speed Valve Location


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

6
Installation Requirements

MODEL LENGTH “A” LENGTH “B” LENGTH “C”


14918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
16918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
18918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
20918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
22918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

7
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.

Requirements
Installation
• 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.
Recommended Lubricant
Type Grade (SAE) Temperature
Roadranger CD50 50 ALL
Transmission Fluid

Includes all Roadranger Approved comparable synthetic lubricant.

Proper Lubricant Level


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

8
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 transmis-
sion 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
TR 12o
20 AN 11o 20'
SM
IS
SI
ON 10o 13'
18 OI
LL
EV
16 EL 9o 16'
TR TO

Percent Grade Converted to Degrees


AN
Limitations for Proper Lubrications

SM BO
IS TT 8o
14 SI OM
ON OF
Percent of Grade

OI FI
12 LL LL
ER
6o 51'
2Q EV
EL HO
UA 1/ LE
10 RT 2" 5o 48'
S BE
LO LO
W W
8 FI
LL 4o 35'
ER
HO
6 LE 3o 26'

4 2o 18'

2 1o 8'

0 0o
0o 1o 2o 3o 4o 5o 6o 7o
Transmission Mounting Angle

Dotted line showing "2 Quarts Low" is for reference only.


Not recommended.

Note: For transmissions with cooler’s 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.

9
Installation Requirements

Air Supply Requirements

1. It is required to use a high quality commercially available air dryer in the air supply line before the transmission.
2. Minimum air requirement for the transmission is 65 PSI.
3. A minimum of 1/4” diameter air supply line is required.
4. The transmission air supply is required to be routed from the air tank, which supplies air to either the front or rear vehi-

Requirements
Installation
cle service brakes, with a gauge indicator in the cab.
5. Transmission airlines should not be routed or attached at the bottom air tank fittings to avoid any chances of introduc-
ing moisture into the airline.
6. Care should be used when routing the air supply to avoid kinks and close contact to heat sources.
7. The transmission air supply must be connected to the air filter/regulator mounted on the range cylinder cover.
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

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

Constant regulated H L
air (55-65 PSI) Slave
Valve S
S P
L
5/32" air line

HI Range Inactive
Air filter/ 1/4" air hose LO Range Pressured
regulator
Top 2 5/32" air line
Solenoid 1/4" air hose
Valve S Constant regulated
P1 air (55-65 PSI) 1/4" air hose
EXH
P2
Constant regulated
5/32" air line air (55-65 PSI)
HI Split Pressured
LO Split Inactive

Range
Cylinder
Splitter
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.

Requirements
Installation

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.

Requirements
Installation

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 N•m], (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.
3. 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 N•m] (3/8-16).

Output Yoke/Flange Installation


Note: The output yoke/flange is supplied with the transmission. If the output Yoke/flange must be replaced, the following proce-
dure 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. Prior to installation, remove all contamination such as styrofoam particles, dust, dirt, or rust in the machined surface of
the yoke/flange.
2. 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.
3. 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 N•m].

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. Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs.
2. Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure engine fly-

Requirements
Installation
wheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of
damage before installation.
3. Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmis-
sion must be in gear in order to rotate the input shaft by turning the output shaft/yoke.
4. 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 prop-
erly 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.
5. If interference is encountered, move the transmission away from the engine to investigate the cause. The use of exces-
sive force to overcome misalignment may cause damage to the transmission input shaft and the clutch.
6. Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines.
7. 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.
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. The transmission nodal mounting pads are approved to be used as a rear engine support location.
2. The OEM is responsible for nodal mount design.
3. Torque transmission nodal mount capscrews (3/4-10 UNC) to 180-190 lbs. ft. [224-258 N•m] of torque

Typical Rear Support Designs

17
Electrical Requirements

Top 2 Valve Electrical Requirements

Mating connector description:

Requirements
Designation Description Part Number Quantity

Electrical
Connector Body 12110293 1
J1 Cable Seal 12048086 3
Terminal 12048074 3
Secondary 12052845 1

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” soft-
ware 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 Top Gear Minus Top Gear Minus Top Gear Ratio
Two Ratio One Ratio
RTLO-XX610B-T2 1.352 1.000 0.741
RTL-XX710B-T2 1.825 1.351 1.000
RTL-XX910B-T2
RTLO-XX713A-T2 1.000 0.856 0.730
RTLO-XX913A-T2
RTLO-XX718B-T2 1.000 0.856 0.730
RTLO-XX918B-T2
RTLOC-1X909A-T2 1.000 0.856 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 oper-
ation 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 To Engine Control Description
Solenoid Valve Module Connector (P1)
A 19 Lockout

Requirements
B none Engine Ground Stud

Electrical
C 20 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 SID Pin Connection
Auxiliary Output #1 26 F-3 OEM Vehicle Interface Connector
Auxiliary Output #2 40 A-2 OEM Vehicle Interface Connector
Auxiliary Output #5 53 W-3 Top 2 3-Way Connector
Auxiliary Output #6 54 X-3 Top 2 3-Way Connector
Auxiliary Output #7 55 Y-3 Top 2 3-Way Connector
Auxiliary Output #8 56 A-1 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 SID Pin Connection
Digital Output 40 V-5 Top 2 3-Way Connector
Digital Output 53 V-6 Top 2 3-Way Connector

21
Electrical Requirements

DDEC III and IV Schematic Diagram

Requirements
Electrical
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

Requirements
Electrical
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
65

31
68

40
56

55
45
60
41

16
26

25
10
30
11
15
61
64

DDEC III and IV OEM Vehicle Interface Connector

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:
• 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.
2. 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. Verify correct clutch adjustment and correct pedal free travel per clutch manufacturer’s requirements.
5. Verify through normal operation that all transmission forward and reverse gears can be obtained. Verify transmission
makes automatic shifts in lever position “AUTO”.
6. Visually check for oil drips or residue on the transmission and related cooler lines, if used.
7. Make sure that the correct transmission dash label is present and that the driver’s instruction booklet is included with
the other vehicle information.
8. 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.
9. Clear fault codes in the engine ECM. Refer to OEM engine literature.

26
Line Inspection

Line Inspection Form

Inspection Sheet

Oem
TOP 2 Chassis S/N
Line Inspection Trans Model # Trans S/N

Description Yes No Corrected


Pre-Start Checks
1. Power Supply check:
2. Oil Fill - Eaton® Roadranger®
DYNO/ROAD TEST CHECKS
4. Correct clutch free travel and adjustment
5. 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? Resume operation.
YES

NO

When Shift Lever is in the "AUTO" The Splitter Button does not work
The Splitter Button does not work,
position, the transmission does not and the transmission does not make
however, the transmission does
make any automatic shifts. Manual automatic shifts in the "AUTO"
make shifts in the "AUTO" position.
splitter shifts are normal. position.

When Shift Lever is in the "AUTO" The Splitter Button does not work
The Splitter Button does not work,
position, the transmission does not and the transmission does not make
however, the transmission does
make any automatic shifts. Manual automatic shifts in the "AUTO"
make shifts in the "AUTO" position.
splitter shifts are normal. position.

Call the Roadranger Call Center Functional? Resume operation.


at 1-800-826-HELP (4357).
NO YES

28
29
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
TO +BATTERY
N/O
RELAY

TO VEHICLE

Caterpillar
COMPONENTS CHECK ENGINE LAMP P2 J2
L994-YL
0.3A CURRENT LIMIT
OFF C WARNING LAMP L994-YL 28 CHECK ENGINE LAMP
B ON 659-PK 659-PK 29 WARNING LAMP
S 0.3A CURRENT LIMIT K998-BU 30 OUTPUT #1
START G880-PK 31 OUTPUT #9
R J906-BR 70 IGNITION KEY SWITCH
NOTE B G881-BU 62 INPUT #12
KEY SWITCH G882-WH 64 INPUT #13
C974-PU 61
S G SPEEDOMETER SIGNAL+
C974-PU 36 SPEEDOMETER POSITIVE
NOTE E
SIGNAL- C973-GN C973-GN 37 SPEEDOMETER NEGATIVE
BAT MTR NOTE H
E718-PK 10 OUTPUT #2
Wiring Diagrams

ALTERNATOR STARTER E991-GY 12 OUTPUT #3


MOTOR G836-WH 13 OUTPUT #4
NOTE B
GROUND (12V) 15
450-YL 16
TACHOMETER SIGNAL+
450-YL 38 TACHOMETER POSITIVE
SAE J1939/13 OFF-BOARD NOTE E
SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
DIAGNOSTIC CONNECTOR NOTE H
NOTE D L901-GY 18 INPUT SENSOR COMMON #1
NOTE D G842-GY 47 INPUT #5 (NOTE L)
+BATTERY B G843-OR 6 INPUT #6 (NOTE L)
-BATTERY A G844-PK 46 INPUT #7 (NOTE L)
- 12V+ - 12V+ - 12V+ J 57
H G933-YL 27 INPUT #9
G 100mA
J1587 DLINK
ATA NEGATIVE E793-BU E793-BU 9 J1587 DATA LINK NEGATIVE
BATTERY 3 BATTERY 2 BATTERY 1 J1587 DLINK
ATA POSITIVE 100mA
F E794-YL E794-YL 8 J1587 DATA LINK POSITIVE
J1939 DATA LINK Shield E A249-BK A249-BK 42 J1939 DATA LINK SHIELD (NOTE K & NOTE M)
J1939 DATA LINK Negative D K990-GN K990-GN 34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)
NOTE J J1939 DATA LINK Positive C K900-YL K900-YL 50 J1939 DATA LINK POSITIVE (NOTE K & NOTE M)
1
TO CHASSIS J1939 DATA LINK 14
ENGINE 10A 26 INPUT #10
BLOCK 101-RD 48 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL
101-RD 52 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL 101-RD
C11, C13, C15, and C18 OEM Diagrams (2003)

53 UNSWITCHED +BATTERY (NOTE D)


14 AWG GXL
229-BK 63 -BATTERY
14 AWG GXL 229-BK 65 -BATTERY
14 AWG GXL 229-BK 67 -BATTERY
14 AWG GXL
SET/RESUME 3 INPUT SENSOR COMMON #2
F713-OR 17 INPUT #14
C978-BR 6.5mA C978-BR 35 SET C453-YL
H795-PK
C979-OR 6.5mA C979-OR 44 RESUME 993-BR
CRUISE CONTROL ON/OFF K999-GN 56 INPUT #1 (NOTE L)
K980-PK 58 INPUT #2 (NOTE L)
6.5mA
H795-PK C975-WH C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
Appendix

K982-YL 60 INPUT #3 (NOTE L)


SERVICE BRAKE PEDAL POSITION N/C
G841-GN 7 INPUT #4 (NOTE L)
H795-PK 6.5mA
C992-PU C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) G837-YL 11 OUTPUT #5
G838-BR 19 OUTPUT #6
COOLING FAN SOLENOID
CLUTCH PEDAL POSITION N/C G839-BU 20 OUTPUT #7
G840-PU 21 OUTPUT #8

45.5mA MAX
H795-PK C977-BU 6.5mA C977-BU 22 CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) RETARDER SOLENOID ON/OFF SWITCH 43
LO
E716-GY E716-GY 23 RETARDER SOLENOID LOW/HI SWITCH
13mA NOTE H MED
H795-PK G879-OR 2 +5V
HI ENGINE RETARDER C983-WH 49 ENGINE COOLANT LEVEL NORMAL (NOTE G)
LO SOLENOID SELECTOR SWITCH C984-YL 54 ENGINE COOLANT LEVEL LOW (NOTE G)
MED
E717-GN E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
HI
A/C HIGH PRESS. SWITCH N/C 51
55
6.5mA NOTE H H795-PK E971-GN E971-GN 41 INPUT #11 (NOTE L)
G834-PU 24 INPUT #15 POSITIVE
PASSIVE G835-OR 25 INPUT #15 NEGATIVE
NOTE C MAGNETIC G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE (NOTE F)
NOTE F VEHICLE SPEED G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
SENSOR 69
G845-PU 68 INPUT #8 (NOTE L)
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMO
RD A C985-BU 40mA C985-BU 4 +8V
+8 V
ACCELERATOR PEDAL POSITION WH C C986-BR 5mA C986-BR 66 ACCELERATOR PEDAL POSITION
J403 P403
ACCELERATOR PEDAL P1 J1
POSITION SENSOR
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 NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
DO NOT CONNECT TO GROUND THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37,
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED 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 REQUIRE
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
TO +BATTERY
N/O
RELAY

TO VEHICLE
COMPONENTS CHECK ENGINE LAMP P2 J2
L994-YL
0.3A CURRENT LIMIT
OFF C WARNING LAMP L994-YL 28 CHECK ENGINE LAMP
B ON 659-PK 659-PK 29 WARNING LAMP
S 0.3A CURRENT LIMIT K998-BU 30 OUTPUT #1
START G880-PK 31 OUTPUT #9
R J906-BR 70 IGNITION KEY SWITCH
NOTE B G881-BU 62 INPUT #12
KEY SWITCH G882-WH 64 INPUT #13
SPEEDOMETER C974-PU 61
S G SIGNAL+
C974-PU 36 SPEEDOMETER POSITIVE
NOTE E
SIGNAL- C973-GN C973-GN 37 SPEEDOMETER NEGATIVE
BAT MTR NOTE H
E718-PK 10 OUTPUT #2
ALTERNATOR STARTER E991-GY 12 OUTPUT #3
MOTOR G836-WH 13 OUTPUT #4
NOTE B
GROUND (12V) 15
450-YL 16
TACHOMETER
C15 OEM Diagrams (2004)

SIGNAL+ 450-YL 38 TACHOMETER POSITIVE


SAE J1939/13 OFF-BOARD NOTE E
SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
DIAGNOSTIC CONNECTOR NOTE H
NOTE D L901-GY 18 INPUT SENSOR COMMON #1
NOTE D G842-GY 47 INPUT #5 (NOTE L)
+BATTERY B G843-OR 6 INPUT #6 (NOTE L)
-BATTERY A G844-PK 46 INPUT #7 (NOTE L)
- 12V+ - 12V+ - 12V+ J 57
H G933-YL 27 INPUT #9
100mA
J1587 DATA LINK NEGATIVE G E793-BU E793-BU 9 J1587 DATA LINK NEGATIVE
BATTERY 3 BATTERY 2 BATTERY 1 100mA
J1587 DATA LINK POSITIVE F E794-YL E794-YL 8 J1587 DATA LINK POSITIVE
J1939 DATA LINK Shield E A249-BK A249-BK 42 J1939 DATA LINK SHIELD (NOTE K & NOTE M)
J1939 DATA LINK Negative D K990-GN K990-GN 34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)
NOTE J J1939 DATA LINK Positive C K900-YL K900-YL J1939 DATA LINK POSITIVE (NOTE K & NOTE M)
50
1
TO CHASSIS J1939 DATA LINK 14
ENGINE 10A 26 INPUT #10
BLOCK 101-RD 48 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL 101-RD 52 UNSWITCHED +BATTERY (NOTE D)
10A 14 AWG GXL 101-RD 53 UNSWITCHED +BATTERY (NOTE D)
14 AWG GXL 229-BK 63 -BATTERY
14 AWG GXL 229-BK 65 -BATTERY
14 AWG GXL
229-BK 67 -BATTERY
14 AWG GXL INPUT SENSOR COMMON #2
SET/RESUME 3
F713-OR 17 INPUT #14
C978-BR 6.5mA C978-BR 35 SET C453-YL
H795-PK
C979-OR 6.5mA C979-OR 44 RESUME 993-BR
CRUISE CONTROL ON/OFF K999-GN 56 INPUT #1 (NOTE L)
K980-PK 58 INPUT #2 (NOTE L)
Appendix

H795-PK C975-WH 6.5mA C975-WH 59 CRUISE CONTROL ON/OFF SWITCH


K982-YL 60 INPUT #3 (NOTE L)
SERVICE BRAKE PEDAL POSITION N/C G841-GN 7 INPUT #4 (NOTE L)
H795-PK C992-PU 6.5mA C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) G837-YL 11 OUTPUT #5
G838-BR 19 OUTPUT #6
COOLING FAN SOLENOID
CLUTCH PEDAL POSITION N/C G839-BU 20 OUTPUT #7
G840-PU 21 OUTPUT #8

45.5mA MAX
H795-PK C977-BU 6.5mA C977-BU 22 CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) RETARDER SOLENOID ON/OFF SWITCH 43
E716-GY 23 RETARDER SOLENOID LOW/HI SWITCH
13mA NOTE H
H795-PK G879-OR 2 +5V
C983-WH 49 ENGINE COOLANT LEVEL NORMAL (NOTE G)
C984-YL 54 ENGINE COOLANT LEVEL LOW (NOTE G)
E717-GN 40 RETARDER SOLENOID MED/HI SWITCH
A/C HIGH PRESS. SWITCH N/C 51
55
6.5mA NOTE H H795-PK E971-GN E971-GN 41 INPUT #11 (NOTE L)
G834-PU 24 INPUT #15 POSITIVE
PASSIVE G835-OR 25 INPUT #15 NEGATIVE
NOTE C MAGNETIC G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE (NOTE F)
NOTE F VEHICLE SPEED G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
SENSOR 69
G845-PU 68 INPUT #8 (NOTE L)
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON
+8 V RD A C985-BU 40mA C985-BU 4 +8V
ACCELERATOR PEDAL POSITION WH C C986-BR 5mA C986-BR 66 ACCELERATOR PEDAL POSITION
J403 P403
ACCELERATOR PEDAL P1 J1
POSITION SENSOR
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 NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
DO NOT CONNECT TO GROUND THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37,
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED 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

30
Appendix
31
SERIES 60 DDEC IV MY2003 EGR
Detroit Diesel

VEHICLE INTERFACE HARNESS OEM RESPONSIBILITY


LABEL WIRE NO CAVITY COLOR
IGNITION GOVERNOR CRUISE CONTROL
COOLANT LEVEL 115 H-3 ORN
LIMITING SPEED GOVERNOR 417 D-2 DK BLUE 953 BLK/WHT WIRE NO COLOR WIRE NO. COLOR
DASH PANEL
CHECK ENGINE LIGHT 419 B-1 PPL/WHT 916 RED/BLK C
DEDICATED 12/24 VDC BATTERY POWER +12/24
IGNITION 439 B-3 PNK MUST BE SOURCED DIRECTLY 417 DK BLUE B GN
DIGITAL INPUT E-1 451 E-1 LT GRN FROM BATTERY POST OR BUS BAR 952 BLK A DIGITAL OUTPUT*
DIGITAL OUTPUT F-3 499 F-3 LT BLU CRUISE
TACHOMETER DRIVE 505 K-1 GRA 1 2 3 440 ORN LIMITING SPEED GOVERNOR ENABLE ON
DIGITAL INPUT* SWITCH
STOP ENGINE LIGHT 509 B-2 PPL (THROTTLE POSITION SENSOR) OFF
A
OI THERMOSTAT OR PTO OR 510 D-1 BRN B RESUME/ACCE
SWITCH ON
EXHAUST BACK PRESSURE (COACH ONLY) 916 RED/BLK DIGITAL INPUT* OFF
SWITCHED C
DIGITAL INPUT H-1 523 H-1 GRA/RED IGNITION WIRE NO COLOR 510 BRN B SET/COAST
952 SWITCH ON
DIGITAL INPUT H-2 524 H-2 GRA OFF 439 PNK BLK A DIGITAL INPUT* OFF
DIGITAL INPUT G-1 528 G-1 BRN/RED F ON
DIGITAL INPUT J-2 531 J-2 ORN + 12/24 VDC VARIABLE SPEED GOVERNOR
G
DIGITAL INPUT J-1 541 J-1 YEL/RED H (POWER TAKE-OFF CONTROL)
J MUST PROVIDE IGNITION POWER DIGITAL INPUT*
DIGITAL INPUT F-1 542 F-1 YEL K - OR - BRAKE ON
DDEC IV Vehicle Interface Harness

IN RUN AND CRANK MODES. SWITCH OFF


DIGITAL INPUT G-2 543 G-2 ORN/BLK 30 WAY CONNECTOR DO NOT SOURCE ANY 510 BRN
OI T-STAT DIGITAL INPUT*
DIGITAL INPUT F-2 544 F-2 BRN/WHT DDC P/N: 12034398 ACCESSORY FROM CIRCUIT 439 CLUTCH ON
DIGITAL INPUT G-3 545 G-3 LT BLUE/YEL TERMINAL SWITCH OFF
DIGITAL OUTPUT A-2 555 A-2 TAN DDC P/N: 12103881 B A 953 BLK/WHT
PLUG
VEHICLE SPEED (+) 556 E-2 LT BLUE/BLK DDC P/N: 12034413
VEHICLE SPEED (-) 557 E-3 LT BLUE/ORN VEHICLE SPEED SENSOR
DIGITAL INPUT K-2 583 K-2 LT BLUE/BLK CONNECTOR
ESS TRANS OR 749 D-3 YEL 556 LT SIGNAL
DDC P/N 12015378
FIRE TRUCK PUMP PRESSURE OR TERMINAL
EXHAUST TEMP DDC P/N 12089188 557 LT BLU/ORN
DATA LINK (+) 900 C-2 DK GREEN/YEL NOTE: RETURN
DATA LINK (-) 901 C-1 DK GREEN * DIGITAL INPUTS AND DIGITAL OUTPUTS FUSE MUST BE PLACED BETWEEN
PWM FAN OR OI ALARM OR 908 J-3 WHT ARE PROGRAMMABLE BY THE OEM MATING CONNECTOR AND BATTERY
PWM TRANSMISSION
SENSOR SUPPLY (5VDC) 916 A-3 RED/BLK
SENSOR RETURN 952 C-3 BLK INSTRUMENT PANEL DIAGNOSTIC CONNECTOR
DIGITAL INPUT K-3 979 K-3 WHT 6-PIN CONNECTOR OEM CONNECTION TO ESH
DIGITAL OUTPUT A-1 988 A-1 GRA WIRE NO. CAVITY COLOR LABEL WIRE NO COLOR
WIRE NO. COLOR STOP ENGINE LIGHT RED 900 A DK GRN/YEL DATA LINK (+)
IGNITION CONNECTOR TWISTED
953 BLK 1 GND (VPOD GND)
RD 901 B DK GRN DATA LINK (-) RELATIVE HUMIDITY/
509 PPL 440 C RED + 12/24 VDC
439 PNK 2 IGN (VPOD POWER)
+12 V FROM BATTERY 440 A ORN TCI 452 BLK
--- D --- PLUG P/N: 23507136 1 3 SENSOR RETURN
BATTERY GROUND 953 B BLK/WHT 953 E BLK/WHT BATTERY GROUND SENSOR 976 WHT
2 4 RELATIVE HUMIDITY
--- F --- PLUG P/N: 23507136
CHECK ENGINE LIGHT YELLOW CONNECTOR 416 GRA 5 SENSOR SUPPLY
3
XXXXX
DDD-XX

YE 910 ORN 6 OI STARTER


419 PPL/WHT CONNECTOR DDC P/N: 23513052 FC/APEX CONNECTOR
COVER DDC P/N: 23513054 4 905 YEL TURBO COMP INLET
7
Appendix

COOLANT LEVEL SENSOR TERMINAL DDC P/N: 23513053


P/N: 54200409 (10-PIN)
+12/24VDC TERMINAL (GOLD) TO OI APEX P/N: 54201016
- OR - P/N: JTP-1811-66AU STARTER TERMINAL
RELAY
9-PIN CONNECTOR APEX P/N:
WIRE NO. CAVITY COLOR WIRE NO. CAVITY COLOR LABEL 565 RED LSP-1811-58AU
TO VEHICLE 8 DIGITAL OUTPUT Y-3
115 A ORN 564 TAN/BLK
953 A BLK/WHT BATTERY GROUND DIGITAL 9 DIGITAL OUTPUT X-3
953 B BLK/WHT 440 B RED +12/24V OUTPUT 563 YEL DIGITAL OUTPUT W-3
925 C DK BLU J1939 DATA LINK (+) WIRING 10
926 D DK BLU/WHT J1939 DATA LINK (-)
12 OR 24 927 E WHT/BLU J1939 SHIELD
(+) VDC SUPPLY (-) 900 F DK GRN/YEL TWISTED DATA LINK (+)
BATTERY BATTERY 901 G DK GRN DATA LINK (-)
POSITIVE NEGATIVE PLUG P/N: 23507136
--- H ---
POWER HARNESS - CRIMP WIRES INTO --- J --- PLUG P/N: 23507136
SINGLE CONNECTOR
280 SERIES AT BATTERY ONLY
COOLANT LEVEL PROBE SINGLE ECM SINGLE FUSE
METRI-PACK 3/8 in. NPT CONNECTOR DDC P/N: 23529496
CONNECTOR DDC P/N: 23520381 COVER DDC P/N: 23529497
DDC P/N: 15300027 1/4 in. NPT TERMINAL DDC P/N: 23507132
TERMINAL CONNECTOR COLOR-
DDC P/N: 23520380 P/N: 12124634 COLOR-RED BLACK
DDC P/N: 12077411 9/16 in. UNF TERMINAL (2) CABLES (4) CABLES
CABLE SEAL P/N: 12077413 REQ'D. REQ'D. WIRE NO. COLOR
DDC P/N: 23522855
DDC P/N: 12015323 CABLE SEAL
ECM P/N: 12015193
SECONDARY LOCK POWER SECONDARY LOCK IGNITION DIGITAL INPUT*
WIRE
* FUSE DIAGNOSITC REQUEST
DDEC P/N: 15300014 CONNECTOR P/N: 12052816 FUSE COMMUNICATION
CAVITY NO. N.O. AND STOP ENGINE WIRE WIRE
953 BLK/WHT CONNECTOR
C 241 OVERRIDE SWITCH CAVITY NO. COLOR LABEL

C
E C E 150

B
B B 150 F 925 DK BLU CAN_H/J 1939 (+) CONTROL DATA LINK

A
D A D 150 E 926 DK BLU/WHT CAN_L/J 1939 (-) CONTROL DATA LINK
A 240
D 927 WHT/BLU CAN_SHLD/J 1939 SHIELD
USE 12 AWG WIRE NOT TO
EXCEED 14 FEET IN LENGTH. COMMUNICATION C 439 PNK IGNITION (OPTIONAL)
B 801 TAN J 1922 (-) DATA LINK
A 440 HARNESS
A 800 TAN/WHT J 1922 (+) DATA LINK
B 953
NOTE:
* FUSES OR CIRCUIT BREAKERS ARE TO BE LOCATED AS CLOSE TO THE
BATTERY AS PRACTICAL AND MUST BE HOUSED WITHIN WEATHERPROOF COMMUNICATIONS CONNECTOR
IGNITION CONNECTOR HOLDER.
CONNECTOR P/N: 12034074 P/N: 12066317
TERMINAL † USE WATERPROOF SPLICES TO SPLICE 12 GA. WIRES TO TERMINAL
P/N: 12089040 APPROPRIATE WIRE GAUGE CABLES FROM BATTERY POWER. P/N: 12103881
PLUG
P/N: 12034413

All information subject to change without notice. (Rev. 8/03)


7SA743 0308 Copyright © 2003 DETROIT DIESEL CORPORATION. 42893
LABEL CAVITY
16
AMBER WARNING LAMP V-1 46 POWER WIRING SPARE DIGITAL & PWM OUTPUTS/INPUTS GOVERNOR CRUISE CONTROL
RED STOP LAMP V-2 1
31 CAVITY LABEL CAVITY LABEL CAVITY DASH PANEL
SERVICE BRAKE RELEASED V-3 THROTTLE PEDAL
V-61 BATTERY (+) V-5 LOW SIDE DIGITAL OUTPUT +12/24V
FAN CONTROL #1 V-4 CAVITY LABEL
V-62 BATTERY (+) 30 AMP DIGITAL OUTPUT
DIGITAL OUTPUT V-5 V-11 SENSOR SUPPLY #1
BATTERY (+) C AUTOMOTIVE
DIGITAL OUTPUT V-6 V-65 BATTERY (+) V-6 LOW SIDE DIGITAL OUTPUT
V-13 ALSG LIMITING CRUISE
B ENABLE
VEHICLE PWR SHUTDOWN V-7 25 V-66 BATTERY (+) SPEED V-9 SWITCH OFF
V-52 PWM OUTPUT V-60 SENSOR RETURN #1 A GOVERNOR ON
RESUME/ACCEL V-8 55
CRUISE ENABLE V-9
10 V-63 BATTERY (-) RESUME/ACCEL ON
V-8 SWITCH
40 V-46 PWM OUTPUT OFF
CLUTCH RELEASED V-10 V-64 BATTERY (-) V-16 IDLE VALIDATION IDLE
BATTERY (-) SET/COAST OFF
SENSOR SUPPLY #1 V-11 V-67 BATTERY (-) VALIDATION V-47 SWITCH
V-59 SENSOR RETURN #2 ON
SENSOR SUPPLY #2 V-12 26 V-48 INPUT (REQUIRED)
56 V-68 BATTERY (-)
SERVICE BRAKE
THROTTLE POSITION V-13 11 IGNITION V-3 SWITCH
INPUT WITH ON
VSG V-14 41 FUSE V-11 SENSOR SUPPLY #1*
1.5kΩ PULL-UP OFF
30 SWITCHED V-11 SENSOR SUPPLY #1 VARIABLE CLUTCH
IGNITION V-15 C V-10 SWITCH
60 V-15 IGNITION SPEED ON
V-60 SENSOR RETURN #1 V-14 VSG
IDLE VALIDATION V-16 15 B OFF
MUST PROVIDE IGNITION POWER GOVERNOR
VEHICLE SPEED SENSOR (+) V-17 45 V-60 SENSOR RETURN #1
A (OPTIONAL) V-59 SENSOR RETURN #2
61 IN RUN AND CRANK MODES.
VEHICLE SPEED SENSOR (-) V-18 DO NOT SOURCE ANY NON-DDEC V-26 INPUT VEHICLE SPEED SENSOR
65 ACCESSORY FROM IGN CIRCUIT (V-15)
NO CONNECTION V-19 64 V-17 SIGNAL
NO CONNECTION V-20 68 SENSOR SUPPLY #1*
INPUT WITH
V-11
1.5kΩ PULL-UP
NO CONNECTION V-21 V-18
DDEC V Vehicle Interface Harness

68-WAY CONNECTOR 18 AWG TERMINAL SHROUD SIDE RETURN


AIR FILTER RESTRICTION V-22 V-60 SENSOR RETURN #1
DDC P/N: 23528252 DDC P/N: 23528271
EXHAUST TEMPERATURE V-23 14 AWG TERMINAL OF CONNECTOR
DDC P/N: 23528272 * NOT USED FOR DIGITAL INPUTS
SEO/DIAG REQUEST V-24 RESISTORS ARE INTERNAL TO ECU
A/C STATUS V-25
ANALOG INPUT - 1.5kΩ PULLUP V-26
TURBO COMPRESSOR IN TEMP V-27 TURBO COMPRESSOR IN TEMP INSTRUMENT PANEL OPTIMIZED IDLE (OPTIONAL)
NO CONNECTION V-28
CAVITY LABEL CAVITY LABEL
EXHAUST BACK PRESSURE OR V-29
RED STOP LAMP CAVITY LABEL
FIRE TRUCK PUMP PRESSURE V-27 TCI 2 TURBO
NO CONNECTION V-30 COMPRESSOR V-02 RSL
V-59 SENSOR RETURN #2 IN TEMP IGN
TACHOMETER V-31 1 V-55 OI ACTIVE LAMP +12/24V
FREQUENCY - SPARE V-32 AMBER WARNING LAMP
FREQUENCY - SPARE V-33 ENGINE COOLANT LEVEL SENSOR - SHUTDOWN V-01 AWL
IGN V-54 OI STARTER +12/24V
NO CONNECTION V-34
CAVITY LABEL
NO CONNECTION V-35 TACH OUTPUT
V-31
NO CONNECTION V-36 V-38 COOLANT LEVEL COOLANT LEVEL V-40 OI ALARM +12/24V
A
ADD COOLANT LEVEL V-37 SENSOR (REFER TO OPTIMIZED IDLE FOR RELAY REQUIREMENTS)
V-60 SENSOR RETURN SHUTDOWN
COOLANT LEVEL - SHUTDOWN V-38 B ENGINE BRAKE SWITCHES
ENGINE BRAKE LOW V-39 V-39 ENG. BRAKE LOW TO PIN D
V-42 OI THERMOSTAT OF
OI ALARM V-40 THERMOSTAT
MAINTENANCE ALERT SYSTEM ONLY ENG. BRAKE MED
AUX SHUTDOWN #1 V-41 V-51 CONNECTOR
Appendix

OI THERMOSTAT V-42 CAVITY LABEL


V-59 SENSOR RETURN
J 1939 DL (+) V-43 ADD COOLANT LEVEL ADD
V-37
J 1939 DL SHIELD V-44 A COOLANT
NO CONNECTION V-45 V-60 SENSOR RETURN LEVEL DIAGNOSTIC REQUEST / STOP ENGINE OVERRIDE
B
PWM OUTPUT V-46 V-24 DIAG REQ/SEO DIAGNOSTIC CONNECTOR
SET/COAST V-47 V-11 SENSOR SUPPLY #1 A DIAGNOSTIC REQ/ CAVITY DDC CONNECTOR LABEL
ANALOG INPUT - 1.5kΩ PULLUP V-48 V-59 SENSOR RETURN SEO SWITCH
AIR
FAN CONTROL OVERRIDE V-49 V-22 AIR FILTER RESTRICTION FILTER - A GND
B - B +12/24 V
PARK BRAKE V-50 RESTRICTION
FAN CONTROL - SINGLE SPEED FAN V-43 C J 1939 DATA LINK (+)
ENG BRAKE MED V-51 V-60 SENSOR RETURN #1 V-58 D J 1939 DATA LINK (-)
C
PWM OUTPUT V-52 V-44 E J 1939 SHIELD
V-25 A/C STATUS V-56 F J 1587 DATA LINK (+)
ETHER START V-53 V-57 G J 1587 DATA LINK (-)
OI STARTER V-54 V-49 FAN CTRL OVERRIDE - H PLUG
V-60 SENSOR RETURN #1 A - J PLUG
OI ACTIVE LAMP V-55
FIRE TRUCK V-59 SENSOR RETURN
J 1587 + V-56 V-11 SENSOR SUPPLY #1
B PUMP
J 1587- V-57 PRESSURE CONNECTOR CAVITY PLUG
V-4 FAN CONTROL #1 DEUTSCH P/N: HD10-9-1939P DEUTSCH P/N: 114017
J 1939 DL (-) V-58 V-29 PUMP PRESSURE +12/24V DDC P/N: 23529496 DDC P/N: 23507136
C
SENSOR RETURN #2 V-59
SENSOR RETURN #1 V-60 PARKING BRAKE & VEHICLE POWER SHUTDOWN TERMINAL CONNECTOR COVER
DEUTSCH P/N: 0460-202-16141 DEUTSCH P/N: HDC16-9
+12V / +24V V-61 COACH APPLICATIONS ONLY V-50 PARK BRAKE DDC P/N: 23507132 DDC P/N: 23529497
+12V / +24V V-62
BATTERY GROUND V-63 V-60 SENSOR RETURN #1 1 V-59 SENSOR RETURN
BATTERY GROUND V-64 EXHAUST
+12V / +24V V-65 V-29 EXHAUST BACK PRESSURE BACK
2
+12V / +24V V-66 PRESSURE V-7 VEHICLE POWER SHUTDOWN
V-11 SENSOR SUPPLY #1 IGN
BATTERY GROUND V-67 3
BATTERY GROUND V-68
V-60 SENSOR RETURN #1 A DDEC V
EXHAUST
All information subject to change without notice. (Rev. 6/05) TEMPERATURE
7SA821 0506 Copyright © 2005 DETROIT DIESEL CORPORATION
V-23 EXHAUST TEMPERATURE
B 40106
VEHICLE INTERFACE HARNESS

32
Appendix
Appendix

Torque Specifications

Part Torque
Flywheel capscrews Follow engine manufacturer’s specifications
Transmission-to-Engine capscrews
7/16-14 * 37 - 50 lbs. ft. [50 - 68 N•m]
3/8-16 * 25 - 32 lbs. ft. [34 - 43 N•m]
M10 x 1-3/8 * 26 - 35 lbs. ft. [35 - 47 N•m]
M10 x 1-3/4 * 26 - 35 lbs. ft. [35 - 47 N•m]
Output yoke nut 450 - 500 lbs. ft. [610 - 678 N•m]
PTO mounting capscrews:
6-bolt opening * 20 - 25 lbs. ft. [27 - 34 N•m]
8-bolt opening * 50 - 65 lbs. ft. [68 - 88 N•m]
Reverse switch (9/16-18) 20 - 25 lbs. ft. [27 - 34 N•m]
Neutral switch/cap (3/4-16) 20 - 25 lbs. ft. [27 - 34 N•m]
Speedometer electronic sensor (3/4-16) 10 - 15 lbs. ft. [14 - 20 N•m]
Lubricant fill plug (1¼-NPT) 60 - 75 lbs. ft. [81 - 101 N•m]
Lubricant drain plug (3/4-NPT) 45 - 55 lbs. ft. [61 - 75 N•m]
Lifting bracket capscrew (3/8-16) 35 - 45 lbs. ft. [47 - 61 N•m]
Rear bearing cover capscrew (3/8-16) 35 - 45 lbs. ft. [47 - 61 N•m]
Transmission nodal mount capscrews (3/4-10) 180 - 190 lbs. ft. [244 - 258 N•m]
Transmission rear support stud nuts (5/8-18) 170 - 185 lbs. ft. [230 - 250 N•m]
Range Air Valve Mounting Screw (#10-24) 21 - 27 lbs. in. [2 - 3 N•m]

* 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. Description
5505027 Volt/Ohm Meter (Standard commercially available VOM)

O.E. Tool & Equipment Group/Kent-Moore SPX Corporation 1-800-328-6657


Kent-Moore Part no. Description
J-43318 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 TRTS-0070
Service Manuals TRSM-0550 - RTLO 10-speed Models
TRSM-0670 - RTLO 13-speed, 18-speed, and Convertible
Models
Illustrated Parts Lists See model specific listing
Driver Instructions 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
Appendix

For additional information call the Roadranger Call Center at 1-800-826-HELP (4357).

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 FUL-
170 (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 3 3, 4 1 NOTE 1 — “A” calculation
Max Max. Peak GCW limit Maximum
Torque Transmission
Gross for Blanket Driveline A1 or A2 must be less than “A ”
Series
H.P. lbs-ft Approval Torque, "A" A1 = Peak Engine Torque x
250 660 RT-6609-A 74,000 Lbs. 9,700 Lowest Gear Ratio
860 RT-8608-L
RT-8908-LL A2 = 672 x W
300 RT-8709-B 80,000 Lbs. M x AR
950 FR-9210B 12,500
Where: W =Weight on drive wheels — Lbs.
1050 10XXX
M =Tire revolution per mile
All Other 11XXX
AR =Axle ratio
1150 RTO-11909-XLL 17,500
370 1250 12XXX NOTE 2 — "A" calculation for Auxiliaries
1350 13XXX 90,000 Lbs. 15,500 NOTE 3 — Transmission Oil Coolers are:
400 1400 T-14607 Recommended — With engines of 350 H.P. and above.
450 1450 All Other 14XXX Required — With engines 400 H.P. and above, and
500 1550 15XXX GCW ’s over 90,000 lbs.
1650 16XXX 140,000 Lbs. — With engines 400 H.P. and above and
1750 17XXX 1400 lbs-ft or greater torque
600 1850 18XXX 17,500 — With engines 450 H.P. and above
2050 RTLO-20913/18 — With engines 1500 lbs-ft and above
RTLO-22918 150,000 Lbs.
700 2250 In all cases, cooler must have sufficient capacity to maintain
2-A-92 9,700 oil temperatures below 250°F at worst case operating
NOTE 2
AT-1202 17,500 conditions.
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
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.
5
On-Highway is defined as limited access and general highways. Grades less than 8%, well maintained, concrete or asphalt surface, no more than 10% off-
highway operation. Maintained gravel, crushed rock, hard packed dirt or similar road surfaces are acceptable when grades are less than 3%.
11/03

35
Appendix

Application Approval Form FUL-170 – Rev. 01/04


Eaton® Fuller®
Transmissions
Approval I.D. No.: Dealer Information
Chassis #(s): Dealership Name:
No. of Vehicles: Dealer Address:
Projected Build Date:
OEM / Plant Location: / Contact:
Customer/Fleet: Telephone: FAX:
APPROVAL REQUEST FOR: Transmission Model Oil Cooler: YES NO
ENGINE INFORMATION:
Make: Model: Displacement: Liters
Rated Horsepower at RPM Peak Torque Lbs-ft at RPM
Governed Speed: RPM Top Speed Limit Setting MPH Cruise Speed MPH
DRIVELINE INFORMATION:
Rear Axle Make: Model: Ratios: /
Drive Tires Make: Model: Size: or Revs/Mile
Retarder Make: Model: Type: HP
Clutch Make: Model:
Trans Case Make: Model: Ratios: /
/Aux. Trans

CHASSIS INFORMATION
Model: Drive Configuration (6x4, 4x2) Vehicle Voltage (12 or 24v) 12 V
Max Weight on Drive Wheels Lbs Max GVW Lbs Max GCW Lbs
VOCATIONAL AND BODY SPECIFIC INFORMATION:
Vocation (Line Haul, Dump, Refuse, Mixer, etc)
Body Type Trailer Type # Trailers
Area of Operation: Country(s) State / Province/Region
Road Usage: Highway % Secondary/City % Off-Highway % Off-Road %
Maximum Grade on Which Vehicle will be Required to Operate %
TRANSMISSION FEATURE / OPTION REQUIREMENTS: (CHECK BOX OF APPROPRIATE CONFIGURATION)
PTO Usage: None 6 Bolt Engine Split-Shaft Countershaft: 6 Bolt 8 Bolt Aux
PTO Model: PTO Driven Equipment:
PERSON SUBMITTING REQUEST PHONE: FAX:
FIRM NAME & ADDRESS:
THIS APPLICATION IS:
ADDITIONAL NOTES / REQUIREMENTS:

SIGNED: APPLICATION ENGINEER: DATE:


1. This Application Approval Form (FUL-170) is intended for use as an approval for warranty Eaton Corporation – TOA
ONLY. An approval indicates that the given configuration meets the minimum requirements of P.O. Box 4013
the specified product; it does not indicate approval to ship the product. Kalamazoo, MI 49003
Appendix

2. All Eaton warranty guidelines apply for coverage and specific labor repair times. Reference Phone: (269) 342-3000
Eaton publications TCWY-0600 and TCWY-0900. Fax: (269) 342-3574
3. Refer to form FUL-169 ( ) for Blanket Application Requirements. TransApplications@Eaton.com

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 spec’ing 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. Eaton Corporation • Truc k Components Operations • P. O. Bo x 4013 • K alamaz oo, MI 490 03 • U.S.A. • www .roadranger .com
Pr inted in US A