Trig 00701007 Installation Guide Fuller Heavy Duty Transmissions

Fuller® Heavy Duty Transmissions

Installation GuideFuller Heavy Duty Transmissions

TRIG0070

October 2007

More time on the road ®

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.

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.

This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.

Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.

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

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

Highly recommended procedures forproper 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.

WARNING

CAUTION

IMPORTANT

Table of ContentsTable of Contents

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

General InformationHow to Use This Manual ............................................1

Installation RequirementsRequirements .............................................................2Space Requirements ..................................................3

10-speed Valve Location ........................................39- / 13-speed Valve Location ..................................518-speed Valve Location ........................................6

Lubrication Requirements ..........................................8Air Supply Requirements ..........................................10

9-speed Pneumatic Diagrams ...............................1110-speed Pneumatic Diagrams .............................1213-speed Pneumatic Diagrams .............................1318-speed Pneumatic Diagrams .............................14

Transmission Mounting Requirements ....................15Mounting Transmission to Engine ........................16Using Rear Supports ............................................17Typical Rear Support Designs ...............................17

Electrical RequirementsTop 2 Valve Electrical Requirements ........................ 18Wiring Diagram OEM Responsibility ........................ 19

Caterpillar Programming ...................................... 19Detroit Diesel Programming ................................. 21

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

AppendixWiring Diagrams ...................................................... 29

Caterpillar ............................................................. 29Detroit Diesel ........................................................ 31

Torque Specifications .............................................. 33Suggested Tools ...................................................... 34Related Publications ................................................ 34Application Forms .................................................... 35

1

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.

2

Installation RequirementsInstallation

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).

Installation Requirements

Space Requirements

10-speed Valve LocationNote: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.

3


Requirements

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


9- / 13-speed Valve Location

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

5


Requirements

18-speed Valve LocationNote: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.


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)

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)

6



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


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.

Includes all Roadranger Approved comparable synthetic lubricant.

Proper Lubricant Level

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).

Recommended Lubricant

Type Grade (SAE) Temperature

Roadranger CD50 Transmission Fluid

50 ALL

Transmission Capacity

9-Speed 28 pints (13.2 liters)

10-Speed 26 pints (12.3 liters)

13/18-Speed 28 pints (13.2 liters)

Improper Oil Level

Hole

Proper Oil Level

Hole

8


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).

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.

12o

11o 20'

10o 13'

9o 16'

8o

6o 51'

5o 48'

4o 35'

3o 26'

2o 18'

1o 8'

0o

0o 1o 2o 3o 4o 5o 6o 7o

22

20

18

16

14

12

10

8

6

4

2

0

Transmission Mounting Angle

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

Proper Lubrication Levels are Essential!

Perc

ent G

rade

Con

verte

d to

Deg

rees

Lim

itatio

ns fo

r Pro

per L

ubric

atio

nsPe

rcen

t of G

rade

TRANSMISSION OIL LEVEL 1/2" BELOW FILLER HOLE

2 QUARTS LOW

TRANSMISSION OIL LEVEL TO BOTTOM OF FILLER HOLE

9


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.

SERVICE TANK

AirDrying

Compressor

Do not tie wrap air line to wire harness on transmission

CAUTION

10


9-speed Pneumatic Diagrams

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

Roadranger valve

HI Range InactiveLO Range Pressured

HI Range PressuredLO Range Inactive

5/32" or 1/8" air line

1/4" air hose

1/4" air hose

HI Range InactiveLO Range Pressured

RangeCylinder

1/4" air hose

Constant regulatedair (55-65 PSI)

Air filter/regulator


1/4" air hoseSplitter Cylinder

5/32" air line

Lock HighExcept DuringTop 2 Function

Top 2 SolenoidValve

HI Split PressuredLO Split Inactive

5/32" air line

5/32" air line


5/32" or 1/8" air line

Slave Valve

H L

S PSL

P1P2

S

EXH

11


Requirements



12




13


Requirements



14


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


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 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


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

18

Electrical RequirementsElectrical

Requirements

Top 2 Valve Electrical Requirements

Mating connector description:

Designation Description Part Number Quantity

Connector Body 12110293 1

J1 Cable Seal 12048086 3

Terminal 12048074 3

Secondary 12052845 1

Electrical Requirements

Wiring Diagram OEM Responsibility

Caterpillar ProgrammingNote: 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:

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.

Transmission Model Top Gear Minus Two Ratio

Top Gear Minus One Ratio

Top Gear Ratio

RTLO-XX610B-T2 1.352 1.000 0.741

RTL-XX710B-T2RTL-XX910B-T2

1.825 1.351 1.000

RTLO-XX713A-T2RTLO-XX913A-T2

1.000 0.856 0.730

RTLO-XX718B-T2RTLO-XX918B-T2

1.000 0.856 0.730

RTLOC-1X909A-T2 1.000 0.856 0.730

19


Requirements

Caterpillar Schematic Diagram

Caterpillar Wiring Diagram

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

19

20

20


Detroit Diesel ProgrammingNote: 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:

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 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

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


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


DDEC V Schematic Diagram

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

23


Requirements

DDEC III, IV and V Wiring Diagram

Typical DDEC III and IV System Overview

ECM DDEC III & IV

Vehicle Interface Connector

Top 2 Valve

24


Typical DDEC V System Overview

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

DDEC III and IV OEM Vehicle Interface Connector

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

ECM DDEC V

Top 2 Valve

5540

25

16110

41

45

30

566015

68

6164

2611

65 4631

25

Line InspectionLine 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

Line Inspection Form

Inspection Sheet

Oem

Chassis S/N

Trans Model # Trans S/N

Description Yes No Corrected

Pre-Start Checks1. Power Supply check:2. Oil Fill - Eaton® Roadranger®

DYNO/ROAD TEST CHECKS4. Correct clutch free travel and adjustment5. All forward and reverse gears obtained

(Including Automatic Shifting Gears)6. Verify no transmission oil leaks7. Verify Top 2 shift label

Drivers Instructions book in cab8. Oil type & brand affixed to vehicle9. Clear Fault Codes in Engine ECMComments

Final Inspection DateSignaturePlease send copy to: Eaton Corp. FAX #(269) 383-5520 ATTN: Automation Installations Groupor mail copy to : Eaton Corp, 13100 E. Michigan Ave., Galesburg, MI 49053 ATTN: Automation Installations Group

TOP 2Line Inspection

27

28

Line InspectionLine Inspection

Troubleshooting

Check for proper lube level.See Lubrication Requirements.

The Splitter Button does not work and the transmission does not make

automatic shifts in the "AUTO"position.

Functional?

NO

YESResume operation.

Check for proper air pressure.See Pneumatic Air Diagrams.

Check transmission power circuits.See Schematic Diagrams for fuse

and ground information.

The Splitter Button does not work,however, the transmission does

make 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 and the transmission does not make

automatic shifts in the "AUTO"position.

The Splitter Button does not work,however, the transmission does

make 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.

Functional?NO YES

Resume operation.Call the Roadranger Call Centerat 1-800-826-HELP (4357).

Appendix

Wiring Diagrams

Caterpillar

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

C977-B

U E

716-G

YG

879-O

RC

983-W

HC

984-Y

L

CLU

TC

H P

ED

AL P

OS

ITIO

N S

WIT

CH

100m

A100m

A

INP

UT

#11 (

NO

TE

L)

INP

UT

#15 P

OS

ITIV

E

RE

TA

RD

ER

SO

LE

NO

ID L

OW

/HI S

WIT

CH

+5V

EN

GIN

E C

OO

LA

NT

LE

VE

L N

OR

MA

L (

NO

TE

G)

EN

GIN

E C

OO

LA

NT

LE

VE

L L

OW

(N

OT

E G

)R

ET

AR

DE

R S

OLE

NO

ID M

ED

/HI S

WIT

CH

INP

UT

#15 N

EG

AT

IVE

VE

HIC

LE

SP

EE

D IN

PO

SIT

IVE

(N

OT

E F

)V

EH

ICLE

SP

EE

D IN

NE

GA

TIV

E IN

PU

T #

8 (

NO

TE

L)

14 A

WG

GX

L14 A

WG

GX

L14 A

WG

GX

L

AC

CE

LE

RA

TO

R P

ED

AL S

EN

SO

R/S

WIT

CH

SE

NS

OR

CO

MM

O+

8V

AC

CE

LE

RA

TO

R P

ED

AL P

OS

ITIO

N

2263

23

2 49

54 41

24

E971-G

NG

834-P

U

62

64

61

0.3

A C

UR

RE

NT

LIM

IT

0.3

A C

UR

RE

NT

LIM

IT

1 2

40

51

55

NO

TE

C: "S

ING

LE

" W

IND

ING

MA

GN

ET

IC P

ICK

UP

SE

NS

OR

RE

CO

MM

EN

DE

D

NO

TE

B: F

OR

SP

EE

DO

ME

TE

RS

OR

TA

CH

OM

ET

ER

S W

ITH

A S

ING

LE

SIG

NA

L IN

PU

T T

ER

MIN

AL, E

ITH

ER

ON

E O

F T

HE

TW

O S

IGN

AL O

UT

PU

T L

INE

S F

RO

M T

HE

EC

M C

AN

BE

US

ED

. LE

AV

E T

HE

RE

MA

ININ

G L

INE

DIS

CO

NN

EC

TE

D,

D

O N

OT

CO

NN

EC

T T

O G

RO

UN

D

5 4 66

25

32

33

69

68

VE

HIC

LE

HA

RN

ES

S C

ON

NE

CT

OR

P2 J

2

H795-P

KC

985-B

UC

986-B

R

L994-Y

L659-P

KK

998-B

UG

880-P

KJ906-B

RG

881-B

UG

882-W

H

SE

RV

ICE

BR

AK

E P

ED

AL P

OS

ITIO

N S

WIT

CH

INP

UT

#7 (

NO

TE

L)

45

C992-P

U

INP

UT

SE

NS

OR

CO

MM

ON

#1

INP

UT

#5 (

NO

TE

L)

INP

UT

#6 (

NO

TE

L)

18

47

6 46

L901-G

YG

842-G

YG

843-O

RG

844-P

K

C974-P

UC

973-G

NE

718-P

KE

991-G

YG

836-W

H

CR

UIS

E C

ON

TR

OL O

N/O

FF

SW

ITC

HIN

PU

T #

3 (

NO

TE

L)

INP

UT

#4 (

NO

TE

L)

59

60

7

C975-W

HK

982-Y

LG

841-G

N

SE

TR

ES

UM

EIN

PU

T #

1 (

NO

TE

L)

INP

UT

#2 (

NO

TE

L)

35

44

56

58

C978-B

RC

979-O

RK

999-G

NK

980-P

K

P1 J

1

G835-O

RG

808-B

UG

809-G

N G

845-P

U

J1587 D

AT

A L

INK

NE

GA

TIV

EJ1587 D

AT

A L

INK

PO

SIT

IVE

J1939 D

AT

A L

INK

SH

IELD

(N

OT

E K

& N

OT

E M

)J1939 D

AT

A L

INK

NE

GA

TIV

E (

NO

TE

K &

NO

TE

M)

J1939 D

AT

A L

INK

PO

SIT

IVE

(N

OT

E K

& N

OT

E M

)

UN

SW

ITC

HE

D +

BA

TT

ER

Y (

NO

TE

D)

UN

SW

ITC

HE

D +

BA

TT

ER

Y (

NO

TE

D)

-BA

TT

ER

Y

INP

UT

#9

INP

UT

#10

INP

UT

SE

NS

OR

CO

MM

ON

#2

INP

UT

#14

52

53

65

67

27 26

3 17

E717-G

N

101-R

D 1

01-R

D

229-B

K

G933-Y

L

C453-Y

L

993-B

R

F713-O

R

9 8 42

34

50

1 14

48

TA

CH

OM

ET

ER

PO

SIT

IVE

TA

CH

OM

ET

ER

NE

GA

TIV

E38

39

57

450-Y

L 4

51-B

R

SP

EE

DO

ME

TE

R P

OS

ITIV

ES

PE

ED

OM

ET

ER

NE

GA

TIV

EO

UT

PU

T #

2O

UT

PU

T #

3O

UT

PU

T #

4

36

37

10

12

13

15

1628

29

30

31

70

+/-

5 V

OLT

S

CH

EC

K E

NG

INE

LA

MP

WA

RN

ING

LA

MP

OU

TP

UT

#1

OU

TP

UT

#9

IGN

ITIO

N K

EY

SW

ITC

HIN

PU

T #

12

INP

UT

#13

E793-B

UE

794-Y

LA

249-B

KK

990-G

NK

900-Y

L

SP

EE

DO

ME

TE

R

NO

TE

EN

OT

E H

NO

TE

B

AC

CE

LE

RA

TO

R P

ED

AL

PO

SIT

ION

SE

NS

OR

40m

A5m

A

BK

RD

WH

J403 P

403

AC

CE

LE

RA

TO

R P

ED

AL S

EN

SO

R/S

WIT

CH

SE

NS

OR

CO

MM

ON

+8 V

AC

CE

LE

RA

TO

R P

ED

AL P

OS

ITIO

N

B A C

H795-P

K

H795-P

K

A/C

HIG

H P

RE

SS

. S

WIT

CH

N/C

E971-G

N

450-Y

L

451-B

R

SIG

NA

L+

SIG

NA

L-

NO

TE

B

TA

CH

OM

ET

ER

NO

TE

EN

OT

E H

E793-B

UE

794-Y

L

10A

PA

SS

IVE

MA

GN

ET

ICV

EH

ICLE

SP

EE

DS

EN

SO

R

G808-B

UG

809-G

N

H795-P

K

H795-P

K

E7

17

-GN

E7

16

-GY

SE

T/R

ES

UM

E

NO

TE

J

NO

TE

DN

OT

E D

EN

GIN

EB

LO

CK

CO

MP

ON

EN

TS

WIT

HIN

TH

IS A

RE

A A

RE

CA

TE

RP

ILLA

R P

RO

VID

ED

CLU

TC

H P

ED

AL P

OS

ITIO

N N

/C

SE

RV

ICE

BR

AK

E P

ED

AL P

OS

ITIO

N N

/C

(PE

DA

L R

ELE

AS

ED

PO

SIT

ION

)

6.5

mA

NO

TE

H

CR

UIS

E C

ON

TR

OL O

N/O

FF

6.5

mA

6.5

mA

6.5

mA

6.5

mA

6.5

mA

CH

EC

K E

NG

INE

LA

MP

WA

RN

ING

LA

MP

+B

AT

TE

RY

-BA

TT

ER

Y

J1587 D

LIN

K N

EG

AT

IVE

AT

A

J1587 D

LIN

K P

OS

ITIV

EA

TA

J1939 D

AT

A L

INK

Positiv

e

J1939 D

AT

A L

INK

Shie

ldJ1939 D

AT

A L

INK

Negative

D

H795-P

K

G CF

SA

E J

1939/1

3 O

FF

-BO

AR

DD

IAG

NO

ST

IC C

ON

NE

CT

OR

B A

TO

VE

HIC

LE

CO

MP

ON

EN

TS

CIR

CU

ITS

WIT

HIN

TH

IS A

RE

A A

RE

RE

CO

MM

EN

DA

TIO

NS

SIG

NA

L-

SIG

NA

L+

ST

AR

T

ON

OF

FB

SC R

H795-P

K

45.5mA MAX

GS

MT

RB

AT

ST

AR

TE

RM

OT

OR

(12V

)

BA

TT

ER

Y 2

N/O

RE

LA

Y

H795-P

KC

985-B

UC

986-B

R

C978-B

RC

979-O

R

C977-B

U

C992-P

U

C975-W

H

C973-G

N

C974-P

UK

EY

SW

ITC

H

659-P

K

GR

OU

ND

L994-Y

L

ALT

ER

NA

TO

R

-12V+

-12V+

+12V

-

BA

TT

ER

Y 3

BA

TT

ER

Y 1

NO

TE

F: IF

AN

ELE

CT

RO

NIC

SIG

NA

L IS

PR

OV

IDE

D IN

PLA

CE

OF

A P

AS

SIV

E

M

AG

NE

TIC

SE

NS

OR

, C

ON

NE

CT

TH

E E

LE

CT

RO

NIC

SIG

NA

L IN

PU

T T

O T

HE

+S

IGN

AL P

IN, T

HE

-S

IGN

AL P

IN S

HO

ULD

NO

T B

E C

ON

NE

CT

ED

O

R G

RO

UN

DE

D W

ITH

ELE

CT

RO

NIC

SIG

NA

L IN

PU

TS

NO

TE

D: T

HE

SE

CO

NN

EC

TIO

NS

AR

E U

NS

WIT

CH

ED

, D

IRE

CT

CO

NN

EC

TIO

N T

O T

HE

BA

TT

ER

Y IS

NO

T R

EQ

UIR

E

NO

TE

CN

OT

E F

LO

ME

D

HI

EN

GIN

E R

ET

AR

DE

RS

OL

EN

OID

SE

LE

CT

OR

SW

ITC

H

NO

TE

H

NO

TE

E: T

HE

EC

M S

PE

ED

OM

ET

ER

AN

D T

AC

HO

ME

TE

R O

UT

PU

T S

IGN

AL L

INE

V

OLT

AG

ES

AR

E Z

ER

O-C

RO

SS

ING

SQ

UA

RE

WA

VE

S. T

HE

SP

EE

DO

ME

TE

R S

IGN

ALS

AT

J1-3

7 A

ND

J1-3

6 A

RE

CO

MP

LE

ME

NT

S O

F E

AC

H O

TH

ER

. T

HE

TA

CH

OM

ET

ER

SIG

NA

LS

AT

J1-3

8 A

ND

J1-3

9 A

RE

CO

MP

LE

ME

NT

S O

F E

AC

H O

TH

ER

. M

AX

IMU

M S

IGN

AL A

MP

LIT

UD

E O

F J

1-3

6, J1-3

7,

J1-3

8, A

ND

J1-3

9 IS

+/-1

0 V

OLT

S. A

MP

LIT

UD

E W

ILL B

E

O

R G

RE

AT

ER

IF

LO

AD

CU

RR

EN

T IS

LE

SS

TH

AN

4m

A.

(PE

DA

L R

ELE

AS

ED

PO

SIT

ION

)

HI

TO

+B

AT

TE

RY

ME

D

LO

RE

TA

RD

ER

SO

LE

NO

ID O

N/O

FF

SW

ITC

H

13m

A

CO

OLIN

G F

AN

SO

LE

NO

ID

OU

TP

UT

#5

OU

TP

UT

#6

OU

TP

UT

#7

OU

TP

UT

#8

11

19

20

21

G837-Y

LG

838-B

RG

839-B

UG

840-P

U

229-B

K-B

AT

TE

RY

J H EA

249-B

KK

990-G

N

K900-Y

L

43

14 A

WG

GX

L

TO

CH

AS

SIS

J1939 D

AT

A L

INK

229-B

K

14 A

WG

GX

L 1

01-R

D

-BA

TT

ER

Y

UN

SW

ITC

HE

D +

BA

TT

ER

Y (

NO

TE

D)

14 A

WG

GX

L14 A

WG

GX

L

10A

10A

29

AppendixAppendix

C15 OEM Diagrams (2004)

C97

7-B

U E

716-

GY

G87

9-O

RC

983-

WH

C98

4-Y

L

CLU

TCH

PE

DA

L P

OS

ITIO

N S

WIT

CH

100m

A10

0mA

INP

UT

#11

(N

OTE

L)

INP

UT

#15

PO

SIT

IVE

RE

TAR

DE

R S

OLE

NO

ID L

OW

/HI S

WIT

CH

+5V

EN

GIN

E C

OO

LAN

T LE

VE

L N

OR

MA

L (N

OT

E G

)E

NG

INE

CO

OLA

NT

LEV

EL

LOW

(N

OT

E G

)R

ETA

RD

ER

SO

LEN

OID

ME

D/H

I SW

ITC

H

INP

UT

#15

NE

GA

TIV

EV

EH

ICLE

SP

EE

D IN

PO

SIT

IVE

(N

OT

E F

)V

EH

ICLE

SP

EE

D IN

NE

GAT

IVE

INP

UT

#8 (

NO

TE

L)

14 A

WG

GX

L14

AW

G G

XL

14 A

WG

GX

L

AC

CE

LER

AT

OR

PE

DA

L S

EN

SO

R/S

WIT

CH

SE

NS

OR

CO

MM

ON

+8V

AC

CE

LER

AT

OR

PE

DA

L P

OS

ITIO

N

2263 23 2 49 54 41 24E

971-

GN

G83

4-P

U

62 64 61

0.3A

CU

RR

EN

T L

IMIT

0.3A

CU

RR

EN

T L

IMIT

1 2

40 51 55

NO

TE

C: "

SIN

GL

E"

WIN

DIN

G M

AG

NE

TIC

PIC

KU

P S

EN

SO

R R

EC

OM

ME

ND

ED

NO

TE

B: F

OR

SP

EE

DO

ME

TER

S O

R T

AC

HO

ME

TE

RS

WIT

H A

SIN

GLE

SIG

NA

L IN

PU

T

T

ER

MIN

AL,

EIT

HE

R O

NE

OF

TH

E T

WO

SIG

NA

L O

UT

PU

T L

INE

S F

RO

M

T

HE

EC

M C

AN

BE

US

ED

. LE

AVE

TH

E R

EM

AIN

ING

LIN

E D

ISC

ON

NE

CT

ED

,

D

O N

OT

CO

NN

EC

T T

O G

RO

UN

D

5 4 6625 32 33 69 68

VE

HIC

LE H

AR

NE

SS

CO

NN

EC

TO

R

P2

J2

H79

5-P

KC

985-

BU

C98

6-B

R

L994

-YL

659-

PK

K99

8-B

UG

880-

PK

J906

-BR

G88

1-B

UG

882-

WH

SE

RV

ICE

BR

AK

E P

ED

AL

PO

SIT

ION

SW

ITC

H

INP

UT

#7

(NO

TE

L)

45C

992-

PU

INP

UT

SE

NS

OR

CO

MM

ON

#1

INP

UT

#5

(NO

TE

L)

INP

UT

#6

(NO

TE

L)

18 47 6 46

L901

-GY

G84

2-G

YG

843-

OR

G84

4-P

K

C97

4-P

UC

973-

GN

E71

8-P

KE

991-

GY

G83

6-W

H

CR

UIS

E C

ON

TR

OL

ON

/OF

F S

WIT

CH

INP

UT

#3

(NO

TE

L)

INP

UT

#4

(NO

TE

L)

59 60 7

C97

5-W

HK

982-

YL

G84

1-G

N

SE

TR

ES

UM

EIN

PU

T #

1 (N

OT

E L

)IN

PU

T #

2 (N

OT

E L

)

35 44 56 58

C97

8-B

RC

979-

OR

K99

9-G

NK

980-

PK

P1

J1

G83

5-O

RG

808-

BU

G80

9-G

N G

845-

PU

J158

7 D

ATA

LIN

K N

EG

ATI

VE

J158

7 D

ATA

LIN

K P

OS

ITIV

EJ1

939

DA

TA L

INK

SH

IEL

D (

NO

TE

K &

NO

TE

M)

J193

9 D

ATA

LIN

K N

EG

ATI

VE

(N

OTE

K &

NO

TE M

)J1

939

DA

TA L

INK

PO

SIT

IVE

(N

OT

E K

& N

OT

E M

)

UN

SW

ITC

HE

D +

BA

TTE

RY

(N

OT

E D

)U

NS

WIT

CH

ED

+B

AT

TER

Y (

NO

TE

D)

-BA

TT

ER

Y

INP

UT

#9

INP

UT

#10

INP

UT

SE

NS

OR

CO

MM

ON

#2

INP

UT

#14

52 53 65 6727 26 3 17

E71

7-G

N

101

-RD

101

-RD

229

-BK

G93

3-Y

L

C45

3-Y

L

993

-BR

F71

3-O

R

9 8 42 34 50 1 14 48

TAC

HO

ME

TE

R P

OS

ITIV

ETA

CH

OM

ET

ER

NE

GA

TIV

E38 39 57

450

-YL

451

-BR

SP

EE

DO

ME

TE

R P

OS

ITIV

ES

PE

ED

OM

ET

ER

NE

GAT

IVE

OU

TP

UT

#2

OU

TP

UT

#3

OU

TP

UT

#4

36 37 10 12 13 15 1628 29 30 31 70

+/-

5 V

OLT

S

CH

EC

K E

NG

INE

LA

MP

WA

RN

ING

LA

MP

OU

TPU

T #1

OU

TPU

T #9

IGN

ITIO

N K

EY

SW

ITC

HIN

PU

T #

12IN

PU

T #

13

E79

3-B

UE

794-

YL

A24

9-B

KK

990-

GN

K90

0-Y

L

SP

EE

DO

ME

TE

RN

OT

E E

NO

TE

H

NO

TE B

AC

CE

LER

ATO

R P

ED

AL

PO

SIT

ION

SE

NS

OR

40m

A5m

A

BK

RD

WH J4

03 P

403

AC

CE

LER

AT

OR

PE

DA

L S

EN

SO

R/S

WIT

CH

SE

NS

OR

CO

MM

ON

+8

VA

CC

ELE

RAT

OR

PE

DA

L P

OS

ITIO

N

B A C

H79

5-P

K

H79

5-P

K

A/C

HIG

H P

RE

SS

. SW

ITC

H N

/C

E97

1-G

N

450-

YL

451-

BR

SIG

NA

L+

SIG

NA

L-

NO

TE B

TAC

HO

ME

TE

RN

OTE

EN

OTE

H

E79

3-B

UE

794-

YL

10A

PA

SS

IVE

MA

GN

ET

ICV

EH

ICLE

SP

EE

DS

EN

SO

R

G80

8-B

UG

809-

GN

H79

5-P

K

H79

5-P

K

SE

T/R

ES

UM

E

NO

TE

J

NO

TE D

NO

TE D

EN

GIN

EB

LOC

K

CO

MP

ON

EN

TS

WIT

HIN

TH

IS A

RE

A A

RE

CA

TE

RP

ILLA

R P

RO

VID

ED

CLU

TC

H P

ED

AL

PO

SIT

ION

N/C

SE

RV

ICE

BR

AK

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NN

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(10-

PIN

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/N: 5

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016

TER

MIN

AL

AP

EX

P/N

: LS

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U

12

3

A B F G H J K

31

AppendixAppendix

DDEC V Vehicle Interface HarnessG

OV

ER

NO

R

C B AC B A

4010

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PR

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IDE

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1

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V-60

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OR

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G

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NS

OR

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N #

1

CAV

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V-61

V-62

V-65

V-66

LAB

EL

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TER

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D

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V-1

V-2

V-3

V-4

V-5

V-6

V-7

V-8

V-9

V-10

V-11

V-12

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V-14

V-15

V-16

V-17

V-18

V-19

V-20

V-21

V-22

V-23

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V-26

V-27

V-28

V-29

V-30

V-31

V-32

V-33

V-34

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V-37

V-38

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V-41

V-42

V-43

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V-48

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V-50

V-51

V-52

V-53

V-54

V-55

V-56

V-57

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ITY

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WE

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IRIN

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AM

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CAV

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D

SE

NS

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EQ

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& V

EH

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WN

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OR

RE

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CAV

ITY

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LAB

EL

EN

GIN

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VE

L S

EN

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R -

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UTD

OW

N

CO

OLA

NT

LEV

EL

SE

NS

OR

S

HU

TDO

WN

A B

CO

OLA

NT

LEV

EL

SE

NS

OR

RE

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N

CAV

ITY

V-37

V-60

LAB

EL

AD

DC

OO

LAN

TLE

VE

LA B

AD

D C

OO

LAN

T LE

VE

L

SE

NS

OR

RE

TUR

N

CAV

ITY

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GD

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/N: 1

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P/N

: 235

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CO

NN

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VE

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/N: H

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DC

P/N

: 235

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7

18 A

WG

TE

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P/N

: 235

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1

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DIG

ITA

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UT

SE

RV

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BR

AK

ES

WIT

CH

IGN

VE

HIC

LE P

OW

ER

SH

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RO

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ON

NE

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R

32

33

Appendix

Torque Specifications

* Thread adhesive sealant required.

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]

34

AppendixAppendix

Suggested Tools

Related Publications

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

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.

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

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 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/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.

• 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.

NOTE 2

Max Gross H.P.

Max. Peak Torque

lbs-ft

TransmissionSeries

GCW limit for Blanket Approval

MaximumDriveline

250 RT-6609-A 74,000 Lbs. 9,700

860

RT-8908-LL

RT-8709-B

300

950

1050

80,000 Lbs.

All Other 11XXX

12,500

1150 RTO-11909-XLL 17,500

1250

370

1350

400 T-14607

90,000 Lbs.

15,500

450 1450 All Other 14XXX

500 15XXX

1650

1750

600 1850

140,000 Lbs.

2050 RTLO-20913/18

700 2250150,000 Lbs.

17,500

2-A-92 9,700

AT-1202 17,500

NOTE 1 — “A” calculation A1 or A2 must be less than “A ” A1 = Peak Engine Torque x Lowest Gear Ratio A2 = 672 x W M x AR

Where: W =Weight on drive wheels — Lbs. M =Tire revolution per mile AR =Axle ratio

NOTE 3 — Transmission Oil Coolers are: Recommended — With engines of 350 H.P. and above. Required — With engines 400 H.P. and above, and

GCW ’s over 90,000 lbs. — With engines 400 H.P. and above and

1400 lbs-ft or greater torque— With engines 450 H.P. and above

— With engines 1500 lbs-ft and above

In all cases, cooler must have sufficient capacity to maintain oil temperatures below 250°F at worst case operating conditions.

Additional Application Requirements for Approval of RTLOC-1X909A-T2:• Application must be for On-Highway 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.

• 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.

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%.

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.

11/03

RT-8608-L

FR-9210B

10XXX

12XXX

13XXX

16XXX

17XXX

18XXX

RTLO-22918

660

1400

1550

• 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.

• 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.

NOTE 2 — "A" calculation for Auxiliaries

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.

Torque, "A"

3 3 3, 4 1

5

5

4

35

AppendixAppendix

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:

Dealer Information

Dealership Name:

Dealer Address:

Contact:

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:

Make: Model: Ratios: / Trans Case /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 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.

Eaton Corporation – TOA

P.O. Box 4013

Kalamazoo, MI 49003

Phone: (269) 342-3000

Fax: (269) 342-3574

[email protected]

36

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 road. O r visit our w eb sit e at www .roadr ang er.com .

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

Roadranger: Eaton, Dana and other trusted partner s providing the best products and services in the industry , ensuring more time on the road.

©20 07 Eaton Corporation · All rights reserved.Pr inted in US A

Copyright Eaton and Dana Corporation,2007. EATON AND DANA CORPORA TIONhereby grants its customer s, vendor s, ordistributor s permission to freely copy,reproduce and/or distribute this documentin printed format. It may be copied only in itsentirety without any changes or modifications.THIS INFORMATION IS NOT INTENDEDFOR SALE OR RESALE, AND THIS NOTICEMUST REMAIN ON ALL COPIES.

Trig 00701007 Installation Guide Fuller Heavy Duty Transmissions

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