All Top 2 transmission systems installed at OEM facilities must meet the requirements for standard manual Eaton Fuller. Transmissions outlined in Form ...
Eaton Fuller Roadranger Transmission Manual
Installation Guide Eaton 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. 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. WARNING 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 Table of Contents Warnings and Cautions Warnings and Cautions ...............................................i 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 Electrical Requirements Top 2 Valve Electrical Requirements ........................ 18 Wiring Diagram OEM Responsibility ........................ 19 Caterpillar Programming ...................................... 19 Detroit Diesel Programming ................................. 21 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. 1 Installation Requirements 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. 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 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) 4 Installation Requirements 9- / 13-speed Valve Location Note: Refer to "Transmission Mounting Requirements" for Valve Spatial Requirements. 5 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) 18-speed Valve Location Note: Refer to "Transmission Mounting Requirements" for Valve Spatial Requirements. Installation Requirements 6 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) 7 Installation Requirements 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. 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 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). Limitations for Proper Lubrications Percent of Grade Percent Grade Converted to Degrees Proper Lubrication Levels are Essential! 22 20 18 16 14 12 10 8 6 TRTARNASNMSIMSSISIOSINO2NOQIOLUILALERLVTEESVLELTLOOW1/B2O"TBTEOLMOWOF FILLER HOLE FILLER HOLE 12o 11o 20' 10o 13' 9o 16' 8o 6o 51' 5o 48' 4o 35' 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 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- 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 5/32" or 1/8" air line HI Range Inactive LO Range Pressured 5/32" or 1/8" air line HI Range Pressured LO Range Inactive Constant regulated HL air (55-65 PSI) Slave 5/32" air line S Valve S L P Top 2 Solenoid Valve 5/32" air line S P1 P2 EXH Constant regulated 5/32" air line air (55-65 PSI) HI Split Pressured LO Split Inactive Air filter/ regulator 1/4" air hose Constant regulated air (55-65 PSI) Splitter Cylinder 1/4" air hose Lock High Except During Top 2 Function HI Range Inactive LO Range Pressured 1/4" air hose 1/4" air hose Range Cylinder 11 Installation Requirements Installation Requirements 10-speed Pneumatic Diagrams Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed. 12 Installation Requirements 13-speed Pneumatic Diagrams Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed. 13 Installation Requirements Installation Requirements 18-speed Pneumatic Diagrams Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed. 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 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. 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 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- 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 transmission 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 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. 5. 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. 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: Designation J1 Description Connector Body Cable Seal Terminal Secondary Part Number 12110293 12048086 12048074 12052845 Quantity 1 3 3 1 Electrical Requirements 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 Top Gear Minus Top Gear Ratio Two Ratio One Ratio 1.352 1.000 0.741 1.825 1.351 1.000 1.000 0.856 0.730 1.000 0.856 0.730 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 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 To Engine Control Module Connector (P1) Description A 19 Lockout B none Engine Ground Stud C 20 Shift Caterpillar Wiring Diagram Electrical Requirements 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 Electrical Requirements DDEC III and IV Schematic Diagram 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 ECM DDEC III & IV Vehicle Interface Connector Top 2 Valve 24 Electrical Requirements Typical DDEC V System Overview ECM DDEC V Top 2 Valve 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 16 46 31 55 40 56 41 60 45 65 68 25 10 26 11 30 1 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 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 · 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 Form Inspection Sheet TOP 2 Line Inspection Line Inspection Oem Chassis S/N Trans Model # Trans S/N Description 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 Yes No Corrected 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 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. Functional? NO Resume operation. YES 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). NO Functional? Resume operation. YES 28 Appendix Wiring Diagrams Caterpillar C11, C13, C15, and C18 OEM Diagrams (2003) 29 CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS N/O RELAY TO +BATTERY OFF C B ON S START R KEY SWITCH ALTERNATOR GROUND S G BAT MTR STARTER MOTOR (12V) TO VEHICLE COMPONENTS NOTE D NOTE D - 12V+ - 12V+ - 12V+ BATTERY 3 BATTERY 2 BATTERY 1 NOTE J CHECK ENGINE LAMP WARNING LAMP L994-YL 0.3A CURRENT LIMIT 659-PK 0.3A CURRENT LIMIT SPEEDOMETER NOTE E NOTE H SIGNAL+ SIGNAL- NOTE B C974-PU C973-GN SAE J1939/13 OFF-BOARD DIAGNOSTIC CONNECTOR TACHOMETER SIGNAL+ NOTE E NOTE H SIGNAL- NOTE B 450-YL 451-BR +BATTERY B -BATTERY A J H J1587 DALTINAK NEGATIVE G J1587 DALITNAK POSITIVE F J1939 DATA LINK Shield E J1939 DATA LINK Negative D J1939 DATA LINK Positive C E793-BU E794-YL A249-BK K990-GN K900-YL 100mA 100mA ENGINE BLOCK TO CHASSIS J1939 DATA LINK 10A 10A 10A SET/RESUME CRUISE CONTROL ON/OFF H795-PK C978-BR 6.5mA C979-OR 6.5mA H795-PK C975-WH 6.5mA SERVICE BRAKE PEDAL POSITION N/C H795-PK C992-PU 6.5mA (PEDAL RELEASED POSITION) CLUTCH PEDAL POSITION N/C COOLING FAN SOLENOID H795-PK (PEDAL RELEASED POSITION) C977-BU 6.5mA RETARDER SOLENOID ON/OFF SWITCH H795-PK 13mA NOTE H A/C HIGH PRESS. SWITCH N/C LO E716-GY MED HI ENGINE RETARDER LO SOLENOID SELECTOR SWITCH MED E717-GN HI 6.5mA NOTE H H795-PK E971-GN 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 45.5mA MAX PASSIVE NOTE C MAGNETIC G808-BU 1 NOTE F VEHICLE SPEED G809-GN 2 SENSOR ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION ACCELERATOR PEDAL POSITION SENSOR BK B H795-PK RD A C985-BU WH C C986-BR J403 P403 40mA 5mA COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED P2 J2 L994-YL 659-PK K998-BU G880-PK J906-BR G881-BU G882-WH C974-PU C973-GN E718-PK E991-GY G836-WH 450-YL 451-BR L901-GY G842-GY G843-OR G844-PK G933-YL E793-BU E794-YL A249-BK K990-GN K900-YL 101-RD 101-RD 101-RD 229-BK 229-BK 229-BK 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 E971-GN G834-PU G835-OR G808-BU G809-GN 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 9 J1587 DATA LINK NEGATIVE 8 J1587 DATA LINK POSITIVE 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 35 SET C453-YL 44 RESUME 56 INPUT #1 (NOTE L) 993-BR 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 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 THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED, SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER. DO NOT CONNECT TO GROUND THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS 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 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 C15 OEM Diagrams (2004) CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS N/O RELAY TO +BATTERY OFF C B ON S START R TO VEHICLE COMPONENTS CHECK ENGINE LAMP WARNING LAMP L994-YL 0.3A CURRENT LIMIT 659-PK 0.3A CURRENT LIMIT KEY SWITCH S G BAT MTR SPEEDOMETER NOTE E NOTE H SIGNAL+ SIGNAL- NOTE B C974-PU C973-GN ALTERNATOR GROUND STARTER MOTOR (12V) NOTE D NOTE D - 12V+ - 12V+ - 12V+ BATTERY 3 BATTERY 2 BATTERY 1 NOTE J SAE J1939/13 OFF-BOARD DIAGNOSTIC CONNECTOR TACHOMETER NOTE E NOTE H SIGNAL+ SIGNAL- +BATTERY B -BATTERY A J H J1587 DATA LINK NEGATIVE G J1587 DATA LINK POSITIVE F J1939 DATA LINK Shield E J1939 DATA LINK Negative D J1939 DATA LINK Positive C E793-BU E794-YL A249-BK K990-GN K900-YL NOTE B 450-YL 451-BR 100mA 100mA ENGINE BLOCK TO CHASSIS J1939 DATA LINK 10A 10A 10A CRUISE CONTROL ON/OFF SET/RESUME H795-PK C978-BR 6.5mA C979-OR 6.5mA H795-PK C975-WH 6.5mA SERVICE BRAKE PEDAL POSITION N/C H795-PK C992-PU 6.5mA (PEDAL RELEASED POSITION) CLUTCH PEDAL POSITION N/C H795-PK (PEDAL RELEASED POSITION) C977-BU 6.5mA RETARDER SOLENOID ON/OFF SWITCH H795-PK 13mA NOTE H COOLING FAN SOLENOID 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL 45.5mA MAX 6.5mA NOTE H A/C HIGH PRESS. SWITCH N/C H795-PK E971-GN ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION ACCELERATOR PEDAL POSITION SENSOR BK B H795-PK RD A C985-BU WH C C986-BR J403 P403 COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED 40mA 5mA NOTE C NOTE F PASSIVE MAGNETIC VEHICLE SPEED SENSOR G808-BU 1 G809-GN 2 P2 J2 L994-YL 659-PK K998-BU G880-PK J906-BR G881-BU G882-WH C974-PU C973-GN E718-PK E991-GY G836-WH 450-YL 451-BR L901-GY G842-GY G843-OR G844-PK G933-YL E793-BU E794-YL A249-BK K990-GN K900-YL 101-RD 101-RD 101-RD 229-BK 229-BK 229-BK 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 E971-GN G834-PU G835-OR G808-BU G809-GN 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 9 J1587 DATA LINK NEGATIVE 8 J1587 DATA LINK POSITIVE 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 35 SET C453-YL 44 RESUME 56 INPUT #1 (NOTE L) 993-BR 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 COMMON 4 +8V 66 ACCELERATOR PEDAL POSITION P1 J1 VEHICLE HARNESS CONNECTOR Appendix 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 C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION TO THE BATTERY IS NOT REQUIRED 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 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 30 Appendix Appendix Detroit Diesel DDEC IV Vehicle Interface Harness DDD-XX XXXXX CB A 31 SERIES 60 DDEC IV MY2003 EGR VEHICLE INTERFACE HARNESS OEM RESPONSIBILITY LABEL WIRE NO CAVITY COLOR COOLANT LEVEL 115 H-3 LIMITING SPEED GOVERNOR 417 D-2 CHECK ENGINE LIGHT 419 B-1 IGNITION 439 B-3 DIGITAL INPUT E-1 451 E-1 DIGITAL OUTPUT F-3 499 F-3 TACHOMETER DRIVE 505 K-1 STOP ENGINE LIGHT 509 B-2 OI THERMOSTAT OR PTO OR 510 D-1 EXHAUST BACK PRESSURE (COACH ONLY) DIGITAL INPUT H-1 523 H-1 DIGITAL INPUT H-2 524 H-2 DIGITAL INPUT G-1 528 G-1 DIGITAL INPUT J-2 531 J-2 DIGITAL INPUT J-1 541 J-1 DIGITAL INPUT F-1 542 F-1 DIGITAL INPUT G-2 543 G-2 DIGITAL INPUT F-2 544 F-2 DIGITAL INPUT G-3 545 G-3 DIGITAL OUTPUT A-2 555 A-2 VEHICLE SPEED (+) 556 E-2 VEHICLE SPEED (-) 557 E-3 DIGITAL INPUT K-2 583 K-2 ESS TRANS OR 749 D-3 FIRE TRUCK PUMP PRESSURE OR EXHAUST TEMP DATA LINK (+) 900 C-2 DATA LINK (-) 901 C-1 PWM FAN OR OI ALARM OR 908 J-3 PWM TRANSMISSION SENSOR SUPPLY (5VDC) 916 A-3 SENSOR RETURN 952 C-3 DIGITAL INPUT K-3 979 K-3 DIGITAL OUTPUT A-1 988 A-1 IGNITION CONNECTOR +12 V FROM BATTERY BATTERY GROUND 440 A 953 B COOLANT LEVEL SENSOR ORN DK BLUE PPL/WHT PNK LT GRN LT BLU GRA PPL BRN 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 123 A B F G H J K 30 WAY CONNECTOR DDC P/N: 12034398 TERMINAL DDC P/N: 12103881 PLUG DDC P/N: 12034413 DK GREEN/YEL DK GREEN WHT RED/BLK BLK WHT GRA ORN BLK/WHT * DIGITAL INPUTS AND DIGITAL OUTPUTS ARE PROGRAMMABLE BY THE OEM INSTRUMENT PANEL WIRE NO. COLOR 509 PPL STOP ENGINE LIGHT RED RD CHECK ENGINE LIGHT YELLOW YE 419 PPL/WHT +12/24VDC WIRE NO. CAVITY 115 A 953 B COLOR ORN BLK/WHT 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 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 POWER HARNESS SINGLE ECM SINGLE FUSE (+) BATTERY POSITIVE 12 OR 24 VDC SUPPLY (-) BATTERY NEGATIVE CRIMP WIRES INTO SINGLE CONNECTOR AT BATTERY ONLY ECM POWER CONNECTOR EC B DA CONNECTOR P/N: 12124634 TERMINAL P/N: 12077413 CABLE SEAL P/N: 12015193 SECONDARY LOCK P/N: 12052816 WIRE CAVITY NO. COLOR-RED (2) CABLES REQ'D. * FUSE C 241 E 150 B 150 D 150 A 240 USE 12 AWG WIRE NOT TO EXCEED 14 FEET IN LENGTH. COLORBLACK (4) CABLES REQ'D. IGNITION FUSE IGNITION CONNECTOR CONNECTOR P/N: 12034074 TERMINAL P/N: 12089040 A 440 B 953 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. IGNITION 953 BLK/WHT DEDICATED 12/24 VDC BATTERY POWER MUST BE SOURCED DIRECTLY FROM BATTERY POST OR BUS BAR 440 ORN SWITCHED IGNITION WIRE NO COLOR OFF 439 PNK ON + 12/24 VDC MUST PROVIDE IGNITION POWER IN RUN AND CRANK MODES. DO NOT SOURCE ANY ACCESSORY FROM CIRCUIT 439 BA CONNECTOR DDC P/N 12015378 TERMINAL DDC P/N 12089188 NOTE: FUSE MUST BE PLACED BETWEEN MATING CONNECTOR AND BATTERY GOVERNOR WIRE NO COLOR 916 RED/BLK C 417 DK BLUE B 952 BLK A LIMITING SPEED GOVERNOR (THROTTLE POSITION SENSOR) 916 RED/BLK C 510 BRN B 952 BLK A VARIABLE SPEED GOVERNOR (POWER TAKE-OFF CONTROL) - OR 510 BRN OI T-STAT CRUISE CONTROL WIRE NO. COLOR +12/24 DIGITAL OUTPUT* DASH PANEL GN DIGITAL INPUT* CRUISE ENABLE SWITCH ON OFF RESUME/ACCE DIGITAL INPUT* SWITCH ON OFF DIGITAL INPUT* SET/COAST SWITCH ON OFF DIGITAL INPUT* DIGITAL INPUT* 953 BLK/WHT BRAKE SWITCH CLUTCH SWITCH ON OFF ON OFF 556 LT VEHICLE SPEED SENSOR SIGNAL 557 LT BLU/ORN RETURN DIAGNOSTIC CONNECTOR 6-PIN CONNECTOR WIRE NO. CAVITY COLOR LABEL 900 901 A B DK GRN/YEL DK GRN TWISTED DATA LINK (+) DATA LINK (-) 440 C RED + 12/24 VDC - - - D - - - PLUG P/N: 23507136 953 E BLK/WHT BATTERY GROUND - - - F - - - PLUG P/N: 23507136 CONNECTOR DDC P/N: 23513052 COVER DDC P/N: 23513054 TERMINAL DDC P/N: 23513053 WIRE NO. 953 440 925 926 927 900 901 - - - - - CAVITY A B C D E F G H J - OR - 9-PIN CONNECTOR COLOR BLK/WHT RED DK BLU DK BLU/WHT WHT/BLU DK GRN/YEL DK GRN - - - - - TWISTED LABEL 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. COLOR DIGITAL INPUT* 953 BLK/WHT N.O. DIAGNOSITC REQUEST AND STOP ENGINE OVERRIDE SWITCH RELATIVE HUMIDITY/ TCI SENSOR CONNECTOR FC/APEX P/N: 54200409 TERMINAL (GOLD) P/N: JTP-1811-66AU TO VEHICLE DIGITAL OUTPUT WIRING OEM CONNECTION TO ESH WIRE NO COLOR 953 BLK 1 439 PNK 2 1 452 BLK 3 2 976 WHT 4 3 416 GRA 5 910 ORN 6 4 905 YEL 7 GND (VPOD GND) IGN (VPOD POWER) SENSOR RETURN RELATIVE HUMIDITY SENSOR SUPPLY OI STARTER TURBO COMP INLET TO OI STARTER RELAY 565 RED 8 564 TAN/BLK 9 563 YEL 10 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 COMMUNICATION HARNESS COMMUNICATION CONNECTOR CAVITY F E D C B A COMMUNICATIONS CONNECTOR P/N: 12066317 TERMINAL P/N: 12103881 PLUG P/N: 12034413 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 All information subject to change without notice. (Rev. 8/03) 7SA743 0308 Copyright © 2003 DETROIT DIESEL CORPORATION. 42893 32 LABEL CAVITY 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-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 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 46 31 55 40 56 41 60 45 65 68 68-WAY CONNECTOR DDC P/N: 23528252 14 AWG TERMINAL DDC P/N: 23528272 All information subject to change without notice. (Rev. 6/05) 7SA821 0506 Copyright © 2005 DETROIT DIESEL CORPORATION 16 1 25 10 26 11 30 15 61 64 POWER WIRING CAVITY V-61 V-62 V-65 V-66 LABEL BATTERY (+) BATTERY (+) BATTERY (+) BATTERY (+) V-63 V-64 V-67 V-68 BATTERY (-) BATTERY (-) BATTERY (-) BATTERY (-) 30 AMP V-15 SWITCHED IGNITION MUST PROVIDE IGNITION POWER IN RUN AND CRANK MODES. DO NOT SOURCE ANY NON-DDEC ACCESSORY FROM IGN CIRCUIT (V-15) BATTERY (+) BATTERY (-) IGNITION FUSE 18 AWG TERMINAL SHROUD SIDE DDC P/N: 23528271 OF CONNECTOR TURBO COMPRESSOR IN TEMP CAVITY LABEL V-27 V-59 TCI 2 SENSOR RETURN #2 1 TURBO COMPRESSOR IN TEMP ENGINE COOLANT LEVEL SENSOR - SHUTDOWN CAVITY LABEL V-38 COOLANT LEVEL A COOLANT LEVEL SENSOR V-60 SENSOR RETURN B SHUTDOWN MAINTENANCE ALERT SYSTEM ONLY CAVITY V-37 V-60 LABEL ADD COOLANT LEVEL A SENSOR RETURN B ADD COOLANT LEVEL V-11 V-22 V-60 SENSOR SUPPLY #1 A AIR FILTER RESTRICTION B SENSOR RETURN #1 C AIR FILTER RESTRICTION V-60 SENSOR RETURN #1 A V-11 SENSOR SUPPLY #1 B V-29 PUMP PRESSURE C COACH APPLICATIONS ONLY V-60 V-29 V-11 SENSOR RETURN #1 1 EXHAUST BACK PRESSURE 2 SENSOR SUPPLY #1 3 V-60 V-23 SENSOR RETURN #1 A EXHAUST TEMPERATURE B FIRE TRUCK PUMP PRESSURE EXHAUST BACK PRESSURE EXHAUST TEMPERATURE Appendix SPARE DIGITAL & PWM OUTPUTS/INPUTS CAVITY LABEL V-5 LOW SIDE DIGITAL OUTPUT V-6 LOW SIDE DIGITAL OUTPUT V-52 PWM OUTPUT V-46 PWM OUTPUT V-48 V-11 V-60 INPUT SENSOR SUPPLY #1* SENSOR RETURN #1 INPUT WITH 1.5k PULL-UP V-26 INPUT V-11 SENSOR SUPPLY #1* V-60 SENSOR RETURN #1 * NOT USED FOR DIGITAL INPUTS RESISTORS ARE INTERNAL TO ECU INPUT WITH 1.5k PULL-UP GOVERNOR CAVITY V-11 V-13 V-60 THROTTLE PEDAL LABEL SENSOR SUPPLY #1 C ALSG B SENSOR RETURN #1 A V-16 V-59 IDLE VALIDATION SENSOR RETURN #2 V-11 V-14 V-60 SENSOR SUPPLY #1 C VSG B SENSOR RETURN #1 A INSTRUMENT PANEL CAVITY LABEL V-02 RSL V-01 V-31 AWL TACH OUTPUT RED STOP LAMP AMBER WARNING LAMP IGN IGN ENGINE BRAKE SWITCHES V-39 ENG. BRAKE LOW V-51 ENG. BRAKE MED V-59 SENSOR RETURN DIAGNOSTIC REQUEST / STOP ENGINE OVERRIDE V-24 V-59 DIAG REQ/SEO SENSOR RETURN DIAGNOSTIC REQ/ SEO SWITCH FAN CONTROL - SINGLE SPEED FAN V-25 A/C STATUS V-49 FAN CTRL OVERRIDE V-59 SENSOR RETURN V-4 FAN CONTROL #1 PARKING BRAKE & VEHICLE POWER SHUTDOWN V-50 PARK BRAKE V-59 SENSOR RETURN +12/24V AUTOMOTIVE LIMITING SPEED GOVERNOR IDLE VALIDATION (REQUIRED) VARIABLE SPEED GOVERNOR (OPTIONAL) CRUISE CONTROL CAVITY DASH PANEL +12/24V DIGITAL OUTPUT V-9 V-8 V-47 V-3 V-10 V-59 V-17 CRUISE ENABLE SWITCH RESUME/ACCEL SWITCH SET/COAST SWITCH OFF ON ON OFF OFF ON SERVICE BRAKE SWITCH ON CLUTCH SWITCH OFF ON OFF SENSOR RETURN #2 VEHICLE SPEED SENSOR SIGNAL V-18 RETURN OPTIMIZED IDLE (OPTIONAL) CAVITY LABEL V-55 OI ACTIVE LAMP +12/24V V-54 OI STARTER +12/24V V-40 OI ALARM +12/24V (REFER TO OPTIMIZED IDLE FOR RELAY REQUIREMENTS) V-42 OI THERMOSTAT TO PIN D OF THERMOSTAT CONNECTOR DIAGNOSTIC CONNECTOR CAVITY V-43 V-58 V-44 V-56 V-57 - DDC CONNECTOR A B C D E F G H J LABEL 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 CONNECTOR DEUTSCH P/N: HD10-9-1939P DDC P/N: 23529496 TERMINAL DEUTSCH P/N: 0460-202-16141 DDC P/N: 23507132 CAVITY PLUG DEUTSCH P/N: 114017 DDC P/N: 23507136 CONNECTOR COVER DEUTSCH P/N: HDC16-9 DDC P/N: 23529497 V-7 VEHICLE POWER SHUTDOWN IGN DDEC V VEHICLE INTERFACE HARNESS 40106 DDEC V Vehicle Interface Harness Appendix 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 (1¼-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) * Thread adhesive sealant required. Torque Follow engine manufacturer's specifications 37 - 50 lbs. ft. [50 - 68 N·m] 25 - 32 lbs. ft. [34 - 43 N·m] 26 - 35 lbs. ft. [35 - 47 N·m] 26 - 35 lbs. ft. [35 - 47 N·m] 450 - 500 lbs. ft. [610 - 678 N·m] 20 - 25 lbs. ft. [27 - 34 N·m] 50 - 65 lbs. ft. [68 - 88 N·m] 20 - 25 lbs. ft. [27 - 34 N·m] 20 - 25 lbs. ft. [27 - 34 N·m] 10 - 15 lbs. ft. [14 - 20 N·m] 60 - 75 lbs. ft. [81 - 101 N·m] 45 - 55 lbs. ft. [61 - 75 N·m] 35 - 45 lbs. ft. [47 - 61 N·m] 35 - 45 lbs. ft. [47 - 61 N·m] 180 - 190 lbs. ft. [244 - 258 N·m] 170 - 185 lbs. ft. [230 - 250 N·m] 21 - 27 lbs. in. [2 - 3 N·m] 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 Service Manuals Illustrated Parts Lists Driver Instructions Lubrication Requirements TRTS-0070 TRSM-0550 - RTLO 10-speed Models TRSM-0670 - RTLO 13-speed, 18-speed, and Convertible Models 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 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® Transmissions Form FUL-169 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/s2 . · 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 speed 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. 250 300 370 400 450 500 600 700 NOTE 2 3 Max. Peak Torque lbs-ft 660 860 950 1050 1150 1250 1350 1400 1450 1550 1650 1750 1850 2050 2250 Transmission Series 3, 4GCW limit for Blanket Approval RT-6609-A RT-8608-L RT-8908-LL RT-8709-B FR-9210B 10XXX 74,000 Lbs. 80,000 Lbs. All Other 11XXX RTO-11909-XLL 12XXX 13XXX 90,000 Lbs. T-14607 All Other 14XXX 15XXX 16XXX 17XXX 18XXX RTLO-20913/18 RTLO-22918 2-A-92 AT-1202 140,000 Lbs. 150,000 Lbs. 1 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 12,500 17,500 15,500 17,500 A2 = 672 x W M x AR Where: W =Weight on drive wheels -- Lbs. M =Tire revolution per mile AR =Axle ratio NOTE 2 -- "A" calculation for Auxiliaries 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 9,700 17,500 In all cases, cooler must have sufficient capacity to maintain oil temperatures below 250°F at worst case operating conditions. Additional Application Requirements for Approval of RTLOC-1X909A-T2: · Application must be for On-Highway5 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. 4Blanket 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% 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 Application Approval Form FUL-170 Rev. 01/04 Approval I.D. No.: Chassis #(s): No. of Vehicles: Projected Build Date: OEM / Plant Location: / Customer/Fleet: Dealership Name: Dealer Address: Dealer Information Contact: Telephone: FAX: APPROVAL REQUEST FOR: Transmission Model Oil Cooler: YES NO ENGINE INFORMATION: Make: Rated Horsepower Governed Speed: Model: at RPM Peak Torque RPM Top Speed Limit Setting Displacement: Liters Lbs-ft at RPM MPH Cruise Speed MPH DRIVELINE INFORMATION: Rear Axle Make: Drive Tires Make: Retarder Make: Clutch Make: Trans Case Make: /Aux. Trans Model: Model: Model: Model: Model: Ratios: Size: Type: Ratios: / or Revs/Mile HP / CHASSIS INFORMATION Model: Drive Configuration (6x4, 4x2) Max Weight on Drive Wheels Lbs Max GVW Vehicle Voltage (12 or 24v) 12 V Lbs Max GCW 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) 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: 1. 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. 2. All Eaton warranty guidelines apply for coverage and specific labor repair times. Reference Eaton publications TCWY-0600 and TCWY-0900. 3. Refer to form FUL-169 ( ) for Blanket Application Requirements. DATE: Eaton Corporation TOA P.O. Box 4013 Kalamazoo, MI 49003 Phone: (269) 342-3000 Fax: (269) 342-3574 TransApplications@Eaton.com Appendix 36 Copyright Eaton Corporation, 2012. Eaton hereby grant their customers, vendors, or distributors 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. Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options. For spec'ing or service assistance, call 1-800-826-HELP (4357) or visit our web site at: www.roadranger.com. In Mexico, call 001-800-826-4357. Eaton Corporation 1111 Superior Ave. Cleveland, OH 44114Acrobat Distiller 7.0 (Windows)