fuller rtlo 16913a

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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

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  • Installation Guide

    Eaton Fuller Heavy-Duty TransmissionsTRIG0070October 2007

    RTLO-11610BRTLO-11610B-T2RTLO-12610BRTLO-12610B-T2RTLO-12713ARTLO-12913ARTLO-13610BRTLO-13610B-T2RTLO-14610ARTLO-14610BRTLO-14610B-T2RTLO-14613BRTLO-14618ARTLO-14713ARTLO-14718BRTLO-14913ARTLO-14918BRTLO-14918B-T2

    RTLO-15610BRTLO-15610B-T2RTLO-16610BRTLO-16610B-T2RTLO-16618ARTLO-16713ARTLO-16713A-T2RTLO-16718BRTLO-16913ARTLO-16913A-T2RTLO-16918BRTLO-16918B-T2RTLO-17610BRTLO-17610B-T2RTLO-18610BRTLO-18610B-T2RTLO-18718BRTLO-18718B-T2

    RTLO-18913ARTLO-18913A-T2RTLO-18918BRTLO-18918B-T2RTLO-20913ARTLO-20918BRTLO-20918B-T2RTLO-22918BRTLOC-16909A-T2RTLOF-11610BRTLOF-11610B-T2RTLOF-12610BRTLOF-12610B-T2RTLOF-12713ARTLOF-12913ARTLOF-13610BRTLOF-13610B-T2RTLOF-14610B

    RTLOF-14610B-T2RTLOF-14613BRTLOF-14618ARTLOF-14713ARTLOF-14718BRTLOF-14913ARTLOF-14918BRTLOF-14918B-T2RTLOF-15610BRTLOF-15610B-T2RTLOF-16610BRTLOF-16610B-T2RTLOF-16618ARTLOF-16713ARTLOF-16713A-T2RTLOF-16718BRTLOF-16913ARTLOF-16913A-T2

    RTLOF-16918BRTLOF-16918B-T2RTLOF-17610BRTLOF-17610B-T2RTLOF-18610BRTLOF-18718BRTLOF-18913ARTLOF-18913A-T2RTLOF-18918BRTLOF-18918B-T2RTLOF-20913ARTLOF-20918BRTLOF-20918B-T2RTLOF-22918BRTLOFC-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

  • 1General 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.

  • 2Installation 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 RequirementsSpace Requirements

    10-speed Valve LocationNote: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.3

  • Installation RequirementsInstallation

    RequirementsMODEL LENGTH A LENGTH B LENGTH C

    11610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)

    12610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)

    13610 815.1 (32.09) 200.4 (7.89) 67.8 (2.67)

    14610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)

    15610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)

    16610 823.2 (32.41) 208.5 (8.21) 75.9 (2.99)4

  • Installation Requirements9- / 13-speed Valve Location

    Note: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.5

  • Installation RequirementsInstallation

    Requirements18-speed Valve LocationNote: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.

    MODEL LENGTH A LENGTH B LENGTH C

    12713 815.1 (32.09) 200.4 (7.89) 43.9 (1.73)

    14713 823.2 (32.41) 208.5 (8.21) 51.8 (2.04

    16713 823.2 (32.41) 208.5 (8.21) 46.5 (1.83)

    12913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

    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

  • Installation RequirementsMODEL LENGTH A LENGTH B LENGTH C

    14918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

    16918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

    18918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

    20918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)

    22918 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)7

  • Installation RequirementsInstallation

    RequirementsLubrication 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

    Hole8

  • Installation RequirementsProper 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 coolers installed, make sure lubricant is level with fill hole opening, run the truck, stop and check lubricant level. Lubricant must be level with fill hole.

    12o11o 20'

    10o 13'

    9o 16'

    8o

    6o 51'

    5o 48'

    4o 35'

    3o 26'

    2o 18'

    1o 8'

    0o0o 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

  • Installation RequirementsInstallation

    RequirementsAir 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

    CAUTION10

  • Installation Requirements9-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

    Constant regulatedair (55-65 PSI)

    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

    Constant regulatedair (55-65 PSI)

    5/32" or 1/8" air line

    Slave Valve

    H L

    S PSL

    P1P2

    S

    EXH11

  • Installation RequirementsInstallation

    Requirements10-speed Pneumatic Diagrams

    Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.12

  • Installation Requirements13-speed Pneumatic Diagrams

    Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.13

  • Installation RequirementsInstallation

    Requirements18-speed Pneumatic Diagrams

    Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.14

  • Installation RequirementsTransmission Mounting Requirements

    Handling

    Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components.

    1. Use a hoist or transmission jack that permits precise control of transmission movement during installation.

    Transmission Preparations

    Always remove banding and protective wrapping from the transmission and inspect for shipping damage as soon as possible upon receiving.

    2. If a thread-in electronic speedometer system is used, tighten sensor or sensor lock nut to 35 lbs-ft. [47 Nm], (3/4-16 threads). If a push-in electronic speedometer system is used, Eaton P/N 14142 (O-ring) and Eaton P/N 71206 (silicon lubricant) are used to seal the sensor.

    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 Nm] (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 Nm]. 15

  • Installation RequirementsInstallation

    RequirementsMounting 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

  • Installation RequirementsUsing 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 Nm] 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 RequirementsWiring 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 0.73019

  • Electrical RequirementsElectrical

    RequirementsCaterpillar 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

    2020

  • Electrical RequirementsDetroit 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 Connector21

  • Electrical RequirementsElectrical

    RequirementsDDEC 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 RequirementsDDEC V Schematic Diagram

    Dig Output (V-5)Dig Output (V-6)23

  • Electrical RequirementsElectrical

    RequirementsDDEC III, IV and V Wiring Diagram

    Typical DDEC III and IV System Overview

    ECM DDEC III & IV

    Vehicle Interface Connector

    Top 2 Valve24

  • Electrical RequirementsTypical 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 463125

  • Line InspectionLine InspectionLine 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 manufacturers 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 drivers 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 InspectionLine Inspection Form

    Inspection Sheet

    OemChassis 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).

  • AppendixWiring 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

    E C

    : "S

    ING

    LE

    " W

    IND

    ING

    MA

    GN

    ET

    IC P

    ICK

    UP

    SE

    NS

    OR

    RE

    CO

    MM

    EN

    DE

    D

    E 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,

    DO

    NO

    T C

    ON

    NE

    CT

    TO

    GR

    OU

    ND

    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

    CC

    ELE

    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

    OM

    PO

    NE

    NT

    S W

    ITH

    IN T

    HIS

    AR

    EA

    AR

    E C

    AT

    ER

    PIL

    LA

    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

    UIT

    S W

    ITH

    IN T

    HIS

    AR

    EA

    AR

    E R

    EC

    OM

    ME

    ND

    AT

    ION

    S

    SIG

    NA

    L-

    SIG

    NA

    L+

    ST

    AR

    T

    ON

    OF

    F

    SC R

    H795-P

    K

    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

    UE

    Y S

    WIT

    CH

    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

    E 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

    10A29

    NO

    T

    NO

    T

    A C

    CIR

    C B 45.5mA MAXK

    NO

    T

  • AppendixAppendixC15 OEM Diagrams (2004)

    C977

    -BU

    E716

    -G

    YG

    879-

    ORC9

    83-W

    HC9

    84-YL

    CLU

    TCH

    PEDA

    L PO

    SITI

    ON SW

    ITCH

    100m

    A10

    0mA

    INPU

    T #1

    1 (N

    OTE

    L)

    INPU

    T #1

    5 PO

    SITI

    VE

    RETA

    RDE

    R SO

    LEN

    OID

    LOW

    /HI S

    WIT

    CH+

    5V ENG

    INE

    COO

    LANT

    LE

    VEL

    NORM

    AL (N

    OTE

    G)

    ENG

    INE

    COO

    LANT

    LE

    VEL

    LOW

    (N

    OTE

    G

    )R

    ETAR

    DER

    SOLE

    NOID

    M

    ED/H

    I SW

    ITCH

    INPU

    T #1

    5 NE

    GAT

    IVE

    VEHI

    CLE

    SPEE

    D IN

    PO

    SITI

    VE (N

    OTE

    F)

    VEHI

    CLE

    SPEE

    D IN

    NE

    GAT

    IVE

    INPU

    T #8

    (N

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