2014 Eaton Fuller Auto Shift and UltraShift Transmissions TRIG0930 Installation Guide Manual - PDF

Installation Guide

Fuller® AutoShift and UltraShift Transmissions TRIG0930 EN-US June 2014

F-5405B-DM3 F-5505B-DM3 F-6405B-DM3 F-6505B-DM3 FM-14D310B-LST FM-15D310B-LST FO-16D313E-LEP FO-5406B-DM3 FO-5505B-DM3 FO-6406B-DM3 FO-6505B-DM3 FOM-16D313E-LEP RTLO-14918A-AS3 RTLO-16913L-DM3 RTLO-16913L-DM3 RTLO-16918A-AS3

RTLO-18918A-AS3 RTLO-20918A-AS3 RTLO-22918A-AS3 RTLOM-16913L-DM3 RTO-10910B-AS3 RTO-10910B-DM3 RTO-12910B-AS3 RTO-12910B-DM3 RTO-14910B-AS3 RTO-14910B-DM3 RTO-14910C-AS3 RTO-16910B-AS3 RTO-16910B-DM3 RTO-16910C-AS3 RTO-18910B-AS3 RTOM-16910B-DM3

Warnings and Cautions

Warnings and Cautions The description and specifications contained in this service publication are current at the time of printing.

Eaton 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.

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

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

!

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

Important: Highly recommended procedures for proper service of this unit.

Note: Additional service information not covered in the service procedures.

Tip: Helpful removal and installation procedures to aid in the service of this unit.

Always use genuine Eaton replacement parts.

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

Warnings and Cautions

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.

Table of Contents

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

Electrical Requirements Requirements .............................................................. 2 System Integration Requirements ............................... 5 Lubrication Requirements ......................................... 16 Cooler Requirements ................................................ 20 Dipstick and Tube Requirements UltraShift AW3 ...... 23 Air Supply Requirements Heavy Duty ....................... 25 Engine Retarder Requirements ................................. 26 Eaton Shift Console Space Requirements ................. 27 Flywheel/Drive Coupler UltraShift AW3 ..................... 30 Medium Duty DM Clutch Installation ......................... 31 Heavy Duty DM Clutch Installation ............................ 33 Transmission Mounting Requirements ..................... 35

Features Cable ......................................................................... 37 Wiring Diagrams OEM Responsibility ....................... 41 Eaton Shift Lever and Tower Space Requirements .... 46 Typical System with Eaton Push Button .................... 49 Typical System with Eaton Shift Lever ...................... 50 Typical System with Eaton Park Shift Lever .............. 51 Typical System with OEM Shift Lever ........................ 52 Typical System with OEM J-1939 Shift Input Device 53 Power Harness .......................................................... 54 Ignition Circuit Detail ................................................. 59 J-1587 Data Link ....................................................... 60 J-1939/15 Data Link .................................................. 61 Dimmer Control Input Connection ............................ 63 Typical Start Enable Circuit ....................................... 64 Typical Ignition Interrupt Circuit (MEIIR) .................. 66 Vehicle Harness Routing ........................................... 68 Outside Cab Features ................................................ 72 Power Take-Off “Split Shaft” ..................................... 73 Power Take-Off “Countershaft driven” ...................... 74 Inertia Brake Relocation Instructions 8 to 6-Bolt PTO Opening ............................................................. 75 Power Take-Off “Thru-Shaft Driven” ......................... 78 UltraShift AW3 Auto Neutral Feature ......................... 79 Auto Neutral and PTO Wiring Diagrams .................... 80

Line Inspection Line Inspection and Road Test Instructions ...............82 Line Inspection Form - UltraShift AW3 ......................85 Line Inspection Form - AutoShift AS3 .......................86 Line Inspection Form - UltraShift DM3 ......................87 Line Inspection Form OEM Wiring Connector/Harness .............................................88 Troubleshooting ........................................................89

Appendix Lifting Eyes and Sensor Positions .............................90 Connector Pin Descriptions .......................................94 UltraShift DM3 6-Speed Wiring Diagram with Analog Shifter .....................................................97 UltraShift DM3 6-Speed Wiring Diagram with Push Button ........................................................99 UltraShift HVP 6-Speed Wiring Diagram with Cable Shifter .....................................................101 UltraShift AW3 6-Speed Wiring Diagram with Analog Shifter ...................................................103 UltraShift AW3 6-Speed Wiring Diagram with Push Button ......................................................105 AutoShift 10-Speed Wiring Diagram with Analog Shifter ...................................................107 AutoShift 10-Speed Wiring Diagram with Push Button ......................................................109 UltraShift 10-Speed Wiring Diagram with Analog Shifter ...................................................111 UltraShift 10-Speed Wiring Diagram with Push Button ......................................................113 UltraShift 13-Speed Wiring Diagram with Analog Shifter ...................................................115 UltraShift 13 Speed Wiring Diagram with Push Button ......................................................117 AutoShift 18-Speed Wiring Diagram with Analog Shifter ...................................................119 AutoShift 18 Speed Wiring Diagram with Push Button ......................................................121 Suggested Tools/Publications .................................123 Torque Specifications ..............................................124 Vendor List ..............................................................127

General Information

This Eaton publication is intended to be a reference guide for the installation of the AutoShift™/ UltraShift™ Gen 3 transmissions.

General vehicle and transmission information is provided to cover 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 additional transmission information, see the Suggested Tools section in the back of this manual. For specific engine information contact the engine OEM. Failure to adhere to Eaton Installation Requirements may affect transmission performance and/or warranty coverage.

AutoShift/UltraShift Gen 3 are compatible with electronically governed engines equipped with a J-1939 data link and certified by Eaton. Transmissions installed at OEM facilities must meet and be approved by Eaton Application Engineering. Contact Eaton Application Engineering or your OEM Application Engineering department for the proper Application form. All applications must be submitted for approval.

OEM facilities must submit a design package to Eaton OEM Engineering Support Group for approval prior to any OEM build. A design package consists of the following information.

Electrical Systems Wiring Schematic: This should show how the AutoShift™/UltraShift™ Gen 3 would interface with the vehicle.

Individual Harness Drawings: This should show the construction of each harness.

Harness Routings: This should show how each harness is routed in the vehicle. The locations of relays, fuses, power connections, tie-downs, etc.

Transmission Air Supply (if required) Transmission Cooling System (if required) Cooler size/type Cooler line routing

Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton makes no warranty, either expressed or implied, based on the information provided. With each new application, engine manufactures should be contacted to make sure desired engines are compatible with these systems.

1

General Information

How to Use this Manual

Installation Requirements

Requirements Eaton AutoShift/UltraShift Gen 3 transmission systems installed at OEM facilities must meet the requirements and be approved using the Eaton Transmission Application Approval Form. Please contact Eaton Application Engineering or your OEM's Application department for the latest Application form.

1.

Cab Floor Access Plate - A cab floor access plate is necessary for access and removal of components from the transmission top. Plate size must be sufficient to allow removal of the transmission Controller or the Electric Shifter.

2.

Clutch Requirements - Power assisted clutch release system is required for all rear engine coach applications. All Heavy Duty AutoShifts require adjustment free clutches. All UltraShift DM3 use the DM Clutch module. It is the OEM responsibility to ensure the engine is not allowed to idle between 625 and 825 rpm with HD UltraShift DM3 clutch modules. Base engine idle is recommended at 625 rpm and all methods (cruise/idle/PTO switch) used to raise the idle have a 200 rpm increment.

3.

Lubrication Requirements - Transmission Gear Box - Eaton® Roadranger® CD50 or equivalent E500 synthetic as specified in Eaton publication TCMT0021.WetClutch for UltraShift AW3 uses synthetic Dexron III, VI, or Allison TransSynd. Approved lubricants are specified in Eaton publication TCMT0021.[see page 16]

4.

Electrical Wiring Requirements - It is the OEM responsibility to provide power and ground to the Transmission Controller (TECU) from a reliable battery source from the battery which supplies the starter. The power (+) connection must include overload protection per Federal Motor Carrier Safety Regulations, Section 393.31.The TECU Main Power and Ground must be a direct connection from the battery posts to the TECU connector. At 120°C, these conductors must be able to carry 30 amps @ 9 volts with no more than 0.05 ohms per wire (0.1 ohms total) for a total voltage drop from the battery posts to the TECU connector not to exceed 3.0 volts.

•

All wiring installation shall conform to Federal Motor Carrier Safety Administration Regulations Sections 393.27 Wiring specifications; 393.28 Wiring to be protected; 393.29 Grounds; 393.31 Overload protective devices; and 393.33 Wiring, installation.[see page 37]

•

The cable for the Deutsch connector shall be:

-

16 GXL max 18 TXL min for Communication and control wires 12 GXL for Power Supply wires 12 GXL or 14 SXL for V-Ignition wires

Note: These sizes are requirements for proper connector sealing and current carrying capacity.[see page 37]

2

•

When the Eaton Push Button Shift Control is used the CAN (Control Area Network communications link between the Shift Control and the Transmission Controller) must be a J-1939/15 twisted pair cable.[see page 49]

•

The J-1939 (the communications link between the Transmission ECU and the Engine Controller ECM) must follow SAE J-1939 specifications for either J-1939/11 or J-1939/15. [see page 61]

•

The diagnostic connector (6-pin required 9-pin recommended) must be easily accessible and mounted on the drivers side of the cab.[see page 60]

•

Splices are not allowed.[see page 37]

•

The Main Power 30 amp fuse connection for the Transmission ECU must be identified with a tag at the battery.[see page 56]

•

Battery Positive and Negative must be disconnected PRIOR to any type of welding on any Eaton Automated transmissionequipped vehicles.[see page 54]

•

Battery Negative must be disconnected PRIOR to removal or installation of ECU harness connectors.[see page 54]

Installation Requirements

The Transmission ECU shall be wired to a Non-switched power source at the battery. If a disconnect switch is required, the recommended practice is to wait a minimum of three minutes before using the disconnect switch. [see page 54]

•

Application of more than 36 volts to the system (such as jump starting) will cause system shutdown and possible electrical component damage.[see page 54]

•

Removal of fuses is not recommended as the method of disconnecting power from the ECU. Making and breaking a circuit through tin plated terminals (e.g. ring terminals, fuses, most connectors) will destroy the plating on the terminal. Opening a switch contact or the main power link is the recommended method of interrupting power.[see page 54]

•

There should be nothing mounted to the TECU, brackets, mounting studs, or contacting the TECU case electrically or mechanically.[see page 68]

•

The transmission wire harness should not be tie wrapped to any cables or hoses. Anchor points on the transmission may be used as long as addition of cables or hoses do not interfere with the existing harness.[see page 68]

•

Harness and in-line connectors shall be anchored to prevent free movement. An anchor point shall be no further than 6 in. [15.24 cm] (recommended 3 in. [7.62 cm]) from a connector. The length of an unanchored section of harness should be no more than 12 in. [30.48 cm].[see page 68]

Note: If a connection to the harness or ECU is required before vehicle installation, Eaton requires the use of a connector with a spring loaded contact rather than a standard mating connector. The spring loaded contact is intended to make the electrical connection with the tip of the terminal without touching the mating surface. This will protect the terminal plating, the NyoGel 760G™ and retain the original durability and reliability of the connector system.[see page 37] Note: Eaton highly recommends the use of (NyoGel 760G) on all electrical contacts and the amount used. For further information contact your Eaton OEM Engineering Support Group.[see page 37] Note: The preferred method of application is to use a metered dispensing mechanism that places the material on the socket of the connector. It is also preferred that the material be placed immediately prior to connector mating to reduce the probability of contamination.[see page 37] 5.

Speedometers - No mechanical speedometers. The 10 o’clock position on Heavy Duty and 12’ o’clock position on Medium Duty are reserved for the Eaton speed sensor.[see page 90]

6.

Neutral Switch - The transmission neutral switch provides an indication of neutral, but does not guarantee a true neutral position or provide a "confirmed neutral" output. This switch must not be used as the sole indication that the transmission is in neutral.

7.

Line Inspection - Each transmission system installed at the OEM must pass the line checklist requirements per the Eaton Line Inspection Form prior to shipment from the OEM plant.[see page 82]

8.

Oil Cooler (UltraShift AW3)- A clutch cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the requirements specified in this document.[see page 20]

9.

Oil Cooler (Heavy Duty) - Transmissions must not be operated at temperatures above 250°F [121°C]. Operation at temperatures above 250°F [121°C] causes loaded gear tooth temperatures to exceed 350°F [177°C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will recur, a cooler should be added, or the capacity of the existing cooling system increased.[see page 20].

10. Engine Retarder - An engine retarder (compression or exhaust) is required on AutoShift 10 and 18-Speed and 13Speed UltraShift transmissions. It is recommended on the 10-Speed UltraShift transmission.The recommended practice is for the exhaust brake on/off switches to be wired in the engine ECM separately from the exhaust brake solenoid.

Failure to comply with this recommended practice can cause Eaton AutoShift/UltraShift transmissions to miss shifts when the exhaust brake is required. For more information contact Eaton Application Engineering and refer to the J-1939 Engine Requirements for Eaton AutomatedTransmissions.[see page 26]

3

Installation Requirements

•

Installation Requirements

11. Lifting Eyes and Sensor Position - The Eaton shift bar housing, ECU, sensor, and lifting eye retaining fasteners as well as those associated with any gasketed transmission surfaces are not intended for use in securing additional OEM brackets. Removal of these can compromise transmission system operation and overall system reliability.[see page 90] 12. Air Dryer Requirements - It is required to use a high quality commercially available air dryer in the air supply line before the transmission.[see page 25] 13. Fan Drive Requirements - The recommended practice is for the engine fan to be wired into the engine ECM, this includes the manual fan override switch. The OEM should use fan clutches that can be controlled by the engine (i.e. electromechanical). Failure to comply with this recommended practice can cause Eaton transmissions to inhibit shifts when the engine fan is on.

14. PTO and Auto Neutral Options - Eaton recommends the OEM provide a connector and wiring coming from the Transmission ECU 38-Way (Vehicle Interface) with the AW3 Auto Neutral and PTO wires installed.[see page 72] 15. Gear Display - The OEM is responsible for supplying the Gear Display, Wiring, and its location per FMVSS.[see page 13] 16. Tone Module - The OEM is responsible for supplying the tone module with the Eaton Shift Lever or OEM Driver Interface Device. The tone module is supplied in the Eaton Push Button Shift Control.[see page 14] 17. Transmission Component Temperature Requirements - The temperature limit for all electrical and air system components is 250F° (121°C). This temperature limit must not be exceeded. If sufficient air gap clearance can not be achieved, the OEM must provide Eaton approved heat shielding.The systems to be protected are the Shift Motors, Sensors, Solenoids, Air Filter Regulator, Inertia Brake, Wire Harness, Transmission Controller, Oil Cooler and Hoses, and the Transmission Case.

18. Engine Configuration - Prior to shipment of Eaton Automated Transmission Systems installed at OEM plants, the engine ECU must contain the proper configuration settings. For the proper engine configuration settings required for Eaton Automated Transmission operation refer to the “Engine Configuration Settings Installation Guide” on roadranger.com under the literature center.

19. Typical Ignition Interrupt Circuit (MEIIR) - There must be no other systems in the ignition circuit between the MEIIR and the engine ECM. If there are other systems in the ignition circuit between the ignition switch and the MEIIR, contact Eaton for guidance.[see page 66] 20. Battery and Ignition Power - Battery and Ignition power and ground to the TECU must not be switched off during the engine start process.[see page 59][see page 56] 21. Engine Idle Speed Nominal Engine Idle Speed UltraShift DM3 UltraShift AW3

4

700 RPM 700 RPM

Installation Requirements

System Integration Requirements AutoShift/UltraShift Gen 3 interfaces with many different components installed on the vehicle such as engine, Shift Input Device, Gear Display, service lamp. SAE J1939 and J1587 data links are standard means to transfer data to other components. Successful System Integration is essential to ensure the utmost satisfactory operation of the vehicle. The following sections summarize AutoShift/UltraShift Gen 3 System Integration Requirements.

SPNs listed below are standard on AutoShift/UltraShift Gen 3. Unused data in a PGN is broadcast as “Not Available”. The inability of Gen 3 to distribute valid data will result in “Error Indicator” or “Not Available” being broadcast. Reference SAE J1939-71 and SAE J1939-73 for complete specification.

Active Diagnostic Trouble Codes 1 (DM1) - pgn65226 Source Address: 3 (Transmission #1) Transmission Repetition Rate: On change, 1 s Start Position

Length

Parameter Name

SPN

1.3

2 bits

Amber Warning Lamp Status

624

Electronic Transmission Controller 1 (ETC1) - pgn61442 Source Address: 3 (Transmission #1) Transmission Repetition Rate: 10 ms Start Position

Length

Parameter Name

SPN

1.1

2 bits

Driveline Engaged

560

1.5

2 bits

Shift In Process

574

2-3

2 bytes

Output Shaft Speed

191

5.1

2 bits

Momentary Engine Overspeed Enable

606

5.3

2 bits

Progressive Shift Disable

607

6-7

2 bytes

Input Shaft Speed

161

5

Installation Requirements

SAE J1939 Data Link Broadcast Messages

Installation Requirements

SAE J1939 Data Link Broadcast Messages: continued Electronic Transmission Controller 2 (ETC2) - pgn61445 Source Address: 3 (Transmission #1) Transmission Repetition Rate: 100 ms for display characters, 1 s for control characters Start Position

Length

Parameter Name

SPN

1

1 byte

Selected Gear

524

2-3

2 bytes

Actual Gear Ratio

526

4

1 byte

Current Gear

523

5-6

2 bytes

Transmission Requested Range

162

7-8

2 bytes

Transmission Current Range

163

Note that the alphanumeric character in byte 7 is to be displayed to the left of the alphanumeric character in byte 8. If only one character is required, then byte 7 shall contain an ASCII space. Byte 8 shall contain the single character.

Defined Control Characters When a control action is sent, the display characters shall not change. For example, if a ‘4’ was shown prior to an arrow being displayed, then a ‘4’ will remain on the display while the request for an arrow is given.

Control Type

Byte 7

Byte 8

Up / Down Arrow

0x00

Tone (Cadence controlled by Gen 3)

Reserved

Bits

8

7

6

5

4

3

2

1

No Arrow Up Arrow Down Arrow Up Arrow & Down Arrow

-

-

-

-

-

-

0 0 1 1

0 1 0 1

0x00

Undefined Tone Off Tone On Undefined

-

-

-

-

1 0 0 1

0 0 1 1

-

-

0x00

Default Unused State

1

1

0

0

-

-

-

-

Electronic Transmission Controller 7 (ETC7) – pgn65098 Source Address: 3 (Transmission #1) Transmission Repetition Rate: 100 ms

6

Start Position

Length

Parameter Name

SPN

4

1 byte

Transmission Requested Gear Feedback

3289

Installation Requirements

SAE J1939 Data Link Broadcast Messages: continued Torque/Speed Control 1 (TSC1) - pgn0 Source Address: 3 (Transmission #1) to either 15 (Retarder – Engine) or 41 (Retarder, Exhaust, Engine #2) Note: TSC1 will be broadcast to the Source Address sending valid Actual Retarder Percent Torque (pgn61440, SPN 520).

Actual Retarder Percent Torque is monitored for valid data from either Source Address 15 or 41. Source Address 41 shall be used anytime valid data is received from both addresses.

Installation Requirements

Transmission Repetition Rate: When actively controlling brake, 50 ms.

Start Position

Length

Parameter Name

SPN

1.1

2 bits

Override Control Mode

695

1.5

2 bits

Override Control Mode Priority

897

4

1 byte

Engine Requested Torque/Torque Limit

518

Torque/Speed Control 1 (TSC1) - pgn0 Source Address: 3 (Transmission #1) to 0 (Engine #1) Transmission Repetition Rate: When actively controlling engine, 10 ms.

Start Position

Length

Parameter Name

SPN

1.1

2 bits

Engine Override Control Mode

695

1.3

2 bits

Engine Requested Speed Control Conditions

696

1.5

2 bits

Override Control Mode Priority

897

2-3

2 bytes

Engine Requested Speed/Speed Limit

898

4

1 byte

Engine Requested Torque/Torque Limit

518

7

Installation Requirements

SAE J1939 Data Link Received Messages Note: Minimum SPNs required to ensure optimal vehicle operation of AutoShift/UltraShift Gen 3 are italicized. Reference SAE J1939-71 and SAE J1939-73 for complete specification.

Component Identification (CI) - pgn65259 Source Address: 5 (Shift Console – Primary) Note: Gen 3 interfacing with J1939 Driver Input Device requires CI within 5 s after it is requested. The accepted CI shall be defined as Model type “RNDML”. “RNDML” must be the first Model characters received by the requester. Additional Model information shall be separated by a dash (RNDML-XXXX).

Transmission Repetition Rate: On request Start Position

Length

Parameter Name

SPN

b

Variable – up to 200 characters

Model

587

Cruise Control/Vehicle Speed (CCVS) - pgn65265 Source Address: 49 (Cab Controller - Primary), 0 (Engine #1), 17 (Cruise Control), 23 (Instrument Cluster #1), 33 (Body Controller), 11 (Brake Controller) Note: First Source Address supported with valid data is latched for power cycle. Source Address sending valid Brake Switch data will be monitored for valid Clutch Switch and Parking Brake Switch data. Wheel-Based Vehicle Speed can be sent from a different Source Address then that sending Brake Switch data.

Transmission Repetition Rate: 100 ms Start Position

Length

Parameter Name

SPN

1.3

2 bits

Parking Brake Switch

70

2-3

2 bytes

Wheel-Based Vehicle Speed

84

4.5

2 bits

Brake Switch

597

4.7

2 bits

Clutch Switch

598

Electronic Engine Controller 1 (EEC1) - pgn61444 Source Address: 0 (Engine #1) Transmission Repetition Rate: Engine Speed Dependent Start Position

Length

Parameter Name

SPN

2

1 byte

Driver’s Demand Engine – Percent Torque

512

3

1 byte

Actual Engine – Percent Torque

513

4-5

2 bytes

Engine Speed

190

Electronic Engine Controller 2 (EEC2) - pgn61443 Source Address: 49 (Cab Controller - Primary), 0 (Engine #1), 17 (Cruise Control), 23 (Instrument Cluster #1), 33 (Body Controller) Transmission Repetition Rate: 50 ms

8

Installation Requirements

Start Position

Length

Parameter Name

SPN

2

1 byte

Accelerator Pedal Position 1

91

Installation Requirements 9

Installation Requirements

SAE J1939 Data Link Received Messages: continued Electronic Engine Controller 3 (EEC3) - pgn65247 Source Address: 0 (Engine #1) Transmission Repetition Rate: 250 ms Start Position

Length

Parameter Name

SPN

1

1 byte

Nominal Friction – Percent Torque

514

5

1 byte

Estimated Engine Parasitic Losses – Percent Torque

2978

Electronic Retarder Controller 1 (ERC1 ) - pgn61440 Source Address: 15 (Retarder – Engine), 41 (Retarder, Exhaust, Engine #1) Transmission Repetition Rate: 100 ms Start Position

Length

Parameter Name

SPN

1.5

2 bits

Retarder Enable – Brake Assist Switch

571

2

1 byte

Actual Retarder – Percent Torque

520

Engine Configuration (EC) - pgn65251 Source Address: 0 (Engine #1) Transmission Repetition Rate: On change of torque/speed points of more than 10% since last transmission. Alternatively, or every 5 s.

10

Start Position

Length

Parameter Name

SPN

1-2

2 bytes

Engine Speed At Idle, Point 1

188

3

1 byte

Percent Torque At Idle, Point 1

539

4-5

2 bytes

Engine Speed At Point 2

528

6

1 byte

Percent Torque At Point 2

540

7-8

2 bytes

Engine Speed At Point 3

529

9

1 byte

Percent Torque At Point 3

541

10-11

2 bytes

Engine Speed At Point 4

530

12

1 byte

Percent Torque At Point 4

542

13-14

2 bytes

Engine Speed At Point 5

531

15

1 byte

Percent Torque At Point 5

543

16-17

2 bytes

Engine Speed At High Idle, Point 6

532

20-21

2 bytes

Reference Engine Torque

544

22-23

2 bytes

Maximum Momentary Engine Override Speed

533

Installation Requirements

SAE J1939 Data Link Received Messages: continued Engine Temperature 1 (ET1) - pgn65262 Source Address: 0 (Engine #1) Transmission Repetition Rate: .5 second Length

Parameter Name

SPN

1

1 byte

Engine Coolant Temperature

110

Installation Requirements

Start Position

Time/Date (TD) - pgn65254 Source Address: Global Transmission Repetition Rate: On request Start Position

Length

Parameter Name

SPN

1

1 byte

Seconds

959

2

1 byte

Minutes

960

3

1 byte

Hours

961

4

1 byte

Month

963

5

1 byte

Day

962

6

1 byte

Year

964

7

1 byte

Local minute offset

1601

8

1 byte

Local hour offset

1602

Transmission Control 1 (TC1) - pgn256 Source Address: 5 (Shift Console – Primary) Note: Gen 3 interfacing with J1939 Driver Input Device requires TC1.

Transmission Repetition Rate: 50 ms Start Position

Length

Parameter Name

SPN

3

1 byte

Transmission Requested Gear

525

Vehicle Distance - pgn65248 Source Address: Global Transmission Repetition Rate: 100 ms Start Position

Length

Parameter Name

SPN

5-8

4 bytes

Total Vehicle Distance

245

11

Installation Requirements

SAE J1587 Data Link Broadcast Messages Note: Unused data in a PID is broadcast as “Not Available”. Reference SAE J1587 for complete specification.

12

Broadcast Period

Parameter Name

PID

100 ms

Transmission Output Shaft Speed

191

400 ms

Text Message to Display Note: PID 226 controls the tone. Cadence of the tone is controlled by Gen 3.

226

500 ms

Transmission Range Selected

162

Transmission Range Attained

163

1.0 s

Battery Potential (Voltage)

168

Upon change or 15 s while fault active

Transmitter System Diagnostic Code and Occurrence Count Table

194

On Request

Clutch Cylinder Position

33

Transmission Synchronizer Brake Value

54

Transmission Actuator Status #2

57

Shift Finger Actuator Status

58

Shift Finger Gear Position

59

Shift Finger Rail Position

60

Transmission Actuator Status #1

63

Vehicle Enabling Component Status

66

Shift Request Shift Status

67

Battery Potential (Voltage) - Switched

158

Transmission Main Shaft Speed

160

Transmission Input Shaft Speed

161

Engine Speed

190

Multi-Section Parameter

192

Diagnostic Data Request/Clear Count

195

Diagnostic Data/Count Clear Response

196

Software Identification

234

Component Identification Parameter

243

Total Vehicle Hours

246

Installation Requirements

Service Lamp AutoShift/UltraShift Gen 3 provide a wired service lamp output at J1-23. This output is designed to drive an incandescent lamp of 1.0 watt or less. The service lamp output will supply a positive voltage equal to the vehicle battery voltage to turn the service lamp on. The OEM must supply the service lamp minus (ground) connection.

Gear Display The OEM is responsible for supplying the Gear Display, Wiring, and its location per FMVSS. Gear Display is required for proper operation of AutoShift/UltraShift Gen 3. Gear Display shall interface with Gen 3 by either SAE J1939 (ETC2) or J1587 (PID 226). The Gear Display offers real-time information pertaining to current engaged gear, engagement status during gear shifting, transmission synchronization during shifting, transmission fault status, diagnostic code information.

Gear Display shall adhere to the following requirements.

1.

For J1587, display time of a message shall be set to 5 seconds to avoid display blanking during heavy bus loads.

2.

Driver shall be able to clearly see the display from the normal driving position continuously during vehicle operation.

3.

Gear Display shall be blank upon initial power up.

4.

Gear Display shall be capable of displaying messages within 2 seconds of ignition key-on.

5.

In order to provide real-time feedback of the selection/shifting/engagement process of transmission, the device must be able to display the received message within 75 Milliseconds.

6.

Whenever bus communications are active and anytime ETC2/PID 226 message is not received within 5 seconds of the last valid message or message received contains a character not supported, the display shall be blank.

7.

Whenever bus communications are not active, a “** ” shall be displayed.

8.

As a minimum, Gear Display must support two character alphanumeric messages with the addition of two sets of display arrows (up and down) either side of the numerals.

9.

Gear Display shall be able to display all two character numeric combinations, upper case alphanumeric combinations, and special characters. See the table below for special characters.

13

Installation Requirements

The service lamp is used to display transmission fault information. However, this fault information is also broadcast via the SAE J1939 and J1587 data links (reference Gen 3 Data Link Requirements for detailed support). Therefore, it is optional that the OEM provide a transmission service lamp. If a service lamp is not part of the OEM Interface Design an OEM wired pigtail connector must be provided that is accessible to a service technician.

Installation Requirements

Minimum Gear Display Special Character Combinations Display -

**

First Character (dec. / hex / char)

Second Character (dec. / hex / char)

32 / 20 / " "

45 / 2D / "-"

32 / 20 / " "

32 / 20 / " "

42 / 2A / "*"

42 / 2A / "*"

Comments

Alert Tone The OEM is responsible for supplying the tone module with the Eaton Shift Lever or OEM Driver Interface Device. The tone module is supplied in the Eaton Push Button Shift Control.

Alert tone shall be required for proper operation of AutoShift/UltraShift Gen 3. The alert tone shall be used to: •

Inform the operator that the transmission has not yet confirmed a Neutral request.

•

Inform the operator that an invalid/improper request or operation was initiated.

•

Implement the shift prompt for AutoSelect fallback mode.

•

Warn of a clutch abuse situation.

The required tone information shall be conveyed from Gen 3 via SAE J1939 (ETC2) and J1587 (PID 226). The OEM is responsible for ensuring at least one annunciator tones when requested by Gen 3. Gen 3 requires an informational tone that consists of a single tone and an alert tone that is continuous until conditions change that prompted the alert.

Annunciator shall adhere to the following requirements.

14

•

Driver shall be able to clearly hear the tone from the normal driving position continuously during vehicle operation.

•

Annunciator shall be capable of responding to a message within 2 seconds of ignition key-on.

•

System equipped with HVP (Park) shall be capable of responding to a message up to 2 minutes after key-off.

•

In order to provide real-time feedback of the selection/shifting/engagement process of transmission, the device must respond to the received message within 75 milliseconds.

•

Whenever bus communications are active and anytime ETC2/PID 226 message is not received within 5 seconds of the last valid message, annunciator shall be silent.

•

Whenever bus communications are not active, annunciator shall be silent.

Installation Requirements

Shift Input Device

The OEM is responsible for ensuring that the designed OEM HIL has the appropriate number of terminating resistors. The Gen 3 transmission ECU includes a terminating resistor with the HIL configuration. The second HIL terminating resistor may either be included in the Shift Input Device or part of the OEM designed HIL harness.

Contact Eaton OEM Application Engineering for Shift Input Device design and interface requirements.

Engine Contact Eaton OEM Application Engineering for engine interface requirements.

15

Installation Requirements

Shift Input Device shall be required for proper operation of AutoShift/UltraShift Gen 3. Shift Input Device for AutoShift/UltraShift Gen3 shall be one of three defined types: analog, J1939 with hardwired Neutral Request signal, or Eaton proprietary HIL. Shift Input Device for HVP shall be an OEM supplied cable shift lever. Although the three types are available, HIL and analog are the recommended interface types. The J1939 Shift Input Device type communicates via the public J1939 link. Due to the unlimited number of components that can interface via the public J1939 link, there is an increased probability of link failure resulting in loss of communication with a J1939 Shift Input Device. This type of failure with a J1939 Shift Input Device reduces the driver’s ability to utilize all transmission modes of operation. Both the HIL and analog Shift Input Device types give the driver the utmost ability to move the truck during a J1939 link failure. An HIL Shift Input Device type shall be the only component that interfaces with the transmission via HIL.

Installation Requirements

Lubrication Requirements AutoShift/UltraShift Gen 3 Transmission Gear Box 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: CAUTION

When adding lubricant, types and brands of lubricant should not be mixed because of possible incompatibility.

Use clean lubricant and clean containers when filling the transmission. Containers that have been used for antifreeze or water should not be used for transmission lubricant.

Additives and friction modifiers are not recommended for use in Eaton Fuller transmissions.

Recommended Lubricant WetClutch for UltraShift AW3 uses synthetic Dexron III, VI, or Allison TransSynd. Approved lubricants are specified in Eaton publication TCMT0021.

Transmission Gear Box - Eaton® Roadranger® CD50 or equivalent E500 synthetic as specified in Eaton publication TCMT0021.

The quantity for proper fill level will vary from unit to unit. The exact amount of oil depends on the transmission inclination and cooling system capacity. Oil level should be checked at room temperature.

Transmission Capacity (Approximate) 5,6-Speed

20.75 pints (9.8 liters)

HVP

23 Pints (10.9 LIters)

10-Speed

26 pints (12.3 liters)

13/18-Speed

28 pints (13.2 liters)

Failure to adhere to Eaton Installation Requirements may affect transmission performance and/or warranty coverage.

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).

DO NOT remove the Electric Shifter (X-Y Shifter) to fill the transmission with oil. The transmission must be filled through the fill hole.

Actual Lube Level

Hole

Improper Oil Level

16

Hole

Proper Oil Level

Actual Lube Level

Installation Requirements

Proper Lubrication Levels as Related to Transmission Installation Angles If the transmission operating angle is more than 12 degrees, improper lubrication can occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees).

For example: If you have a 4 degree transmission mounting angle, then 8 degrees (or 14 percent of grade) is equal to the limit of 12 degrees. If you have a 0 degree mounting angle, the transmission can be operated on a 12 degree (21 percent) grade.

Installation Requirements

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) grade.

Limitations for P roper L ubrications 22 TR

AN

20

SM

IS

SI

18

OI

LL

16

Percent of G rade

ON

EV

EL

TR

AN

TO

SM

IS

14

BO

TT

OM

SI

ON

OI

OF

LL

12

2Q

EL

UA

RT

10

FIL

LE

EV

S

R

HO

LE

1/2

"B

LO

EL

OW

W

8

FIL

LE

R

HO

LE

6 4 2 0

0¡

1¡

2¡

3¡

4¡

5¡

6¡

7¡

Transmission Mounting Angle Dotted line showing "2 Q uarts L ow" is for reference only. Not recommended

Note: For transmission’s with cooler’s installed, make sure the lubricant is level with the fill hole opening, run the truck, stop and check lubricant level.

Note: This levels in this chart refer to a Heavy Duty transmission.

17

Installation Requirements

UltraShift AW3 WetClutch Lubrication Requirements 1.

Synthetic Dexron® III, VI, or Allison TransSynd must be used in the WetClutch section of the transmission. Oil must be filled to the proper level prior to OEM shipment. a.

Make sure oil is within dipstick marks.

b.

Oil should be checked at idle in neutral.

c.

Oil checks can be performed when the oil temperature is 60° to 120°F. The oil level should be within the dipstick Full and Add marks.

d.

The operational level should always be within the operating marks on the dipstick. The exact amount of oil depends on the transmission inclination and cooling system capacity.

e.

Insufficient oil damages the pump and other components and can affect the function and reduce the life of the transmission CAUTION

DO NOT OVERFILL. This causes foaming, overheating, loss of fuel economy and possibly not shifting.

When adding oil, types and brands of oil should not be mixed because of possible incompatibility.

Use clean oil and clean containers when filling the transmission. Containers that have been used for anti-freeze or water should not be used for transmission oil.

A label identifying OEM filled “clutch lube synthetic Dexron III/VI” is required near the dipstick tube opening. See figure below.

CHECK OIL LEVEL AT ENGINE IDLE IN NEUTRAL FACTORY FILLED WITH SYNTHETIC DEXRON¨ III/VI Eaton¨ Fuller¨

18

Installation Requirements

UltraShift AW3 WetClutch Oil Fill Procedure Remove the dipstick and add an initial fill 18 pints (8.5 liters) of the specified oil through the fill tube (dipstick tube).

2.

Place the transmission in the neutral position and apply the parking brakes. Start the engine and let it idle for five (5) minutes, (this allows the oil to circulate and fill the cooling system).

3.

Add oil as needed to obtain the correct level.

4.

Increase the engine idle slowly to 1500 RPM for two (2) minutes.

5.

Check the oil level at normal idle speed in neutral, add or drain oil to make sure it is at the proper level on the dipstick (between the cold ADD mark and cold FULL mark).

6.

Replace the dipstick and tighten securely.

WetClutch Dipstick/Fill Tube Location

Transmission Gear Box Oil Fill Plug

WetClutch +

Vehicle Cooling system =

Total WetClutch Oil Capacity responsibility)

(OEM

Initial Fill 18 pints or (8.5 liters)

Varies depending upon application

Varies depending on oil cooler capacity

19

Installation Requirements

1.

Installation Requirements

Cooler Requirements Heavy Duty UltraShift/AutoShift Gen 3 Cooler Requirements •

Transmissions must not be operated at temperatures above 250°F [121°C]. Operation at temperatures above 250°F [121°C] causes loaded gear tooth temperatures to exceed 350°F [177°C] which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an unusual operating condition that will recur, a cooler should be added, or the capacity of the existing cooling system increased.

•

The following conditions in any combination can cause operating temperatures of over 250°F (120°C):[see page 20].

•

Operating consistently at high loads/slow speeds

•

High ambient temperatures

•

Restricted air flow around the transmission

•

Exhaust system too close to the transmission

•

High horsepower operation

•

Engine Retarders

External oil coolers are available to reduce operating temperatures when the above conditions are encountered. Eaton Oil cooler systems must meet a minimum requirement of 3/4 I.D. cooler lines and 8 GPM. system flow @ 1500 RPM. The end user is ultimately responsible for maintaining transmission lube temperatures below 250°F [121°C].

Transmission Oil Coolers are recommended

Transmission Oil Coolers are required

With engines of 350 H.P. and above

With engines 400 H.P. and above and GCW’s of 90,000 lbs [40,823 kg] or greater With engines 400 H.P. and above and 1400 lbs. ft. [1898 N•m] or Greater torque With engines 450 H.P. and above With engines 1500 lbs. ft. [2033 N•m] and above

20

Installation Requirements

UltraShift AW3 Cooler Requirements A clutch cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the requirements specified in this document.

2.

The maximum pressure drop through the transmission cooler is 10 PSI @ 8 GPM of oil flow (at normal operating temperatures).

3.

Coolers must be sized according to the following requirements and be able to provide minimum heat extraction rates with the vehicle stationary, engine idling at normal operating temperature, and oil flow at 6 gallons per minute.

•

GCW less 33,000 -- 450 BTU/Min.

•

GCW greater 33,000 --700 BTU/Min.

•

Severe service and GCW greater than 43,000 -- 1000 BTU/Min. Applications include refuse, tankers, construction equipment such as dump trucks, concrete mixers, and off road equipment.

4.

Transmission cooler must withstand operating pressure up to 300 PSI.

5.

The cooler and cooler connecting lines should be free of debris, dirt, grease, etc. before being attached to the transmission. If these conditions exist, cooler lines must be flushed or cleaned.

6.

The cooler must meet Eaton application guidelines and requirements in this document unless specifically approved by Eaton.

7.

A minimum of SAE # 12 (3/4 inch) cooler hose or comparable tubing must be used for the Eaton UltraShift AW3 transmission cooler circuit.

8.

Cooler connecting lines should be routed in such a way as to prevent kinks or leaks from rubbing on other components.

Use high temperature protection as required to protect against heat deterioration.

21

Installation Requirements

1.

Installation Requirements

Oil To Water Cooler Requirements AW3 Transmission Cooling System Without Remote Bypass

R A D I A T O R

WC OUT TO OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 O-RING FITTING, 37 DEGREE FLARED FITTING (OEM SUPPLIED)

TO WATER PUMP

WATER TO COOLER

WC IN FROM OIL COOLER 1-1/16 - 12 UN-2B FOR SAE-12 O-RING FITTING, 37 DEGREE FLARED FITTING (OEM SUPPLIED)

OIL COOLER

OIL COOLER - MINIMUM #12 RECOMMENDED OIL FROM COOLER TO TRANSMISSION

THERMOSTAT RADIATOR LINERS and HEADS OIL COOLER

PUMP

22

T C COOLER

Installation Requirements

Dipstick and Tube Requirements UltraShift AW3 The dipstick and fill tube design must provide an acceptable means of checking the transmission WetClutch portion oil level. New dipstick and tube designs require approval and/or validation by Eaton.

2.

A vented dipstick tube design is required.

3.

A supporting bracket to eliminate vibration is required at the upper end of the dipstick tube. The bracket must be attached to the transmission or engine and not to the frame or body

4.

A minimum overall vertical rise of 6” must be maintained above the clutch housing oil pan mounting surface for oil filling.

5.

The first section of the dipstick tube must be vertical from the oil pan connector, a minimum of 2.5” above the clutch housing oil pan mounting surface, to insure accurate level readings.

6.

Horizontal or near horizontal runs, sharp tight and excessive bends are prohibited in the tube design as they adversely affect oil fill time and accurate level readings.

7.

Torque dipstick tube fitting (1 5/8-12 UN-2A) to 60-70 lbs. ft. [81-95 N•m].

8.

Actual oil level must be within Eaton specifications according to the dipstick readings.

9.

Dipstick must be marked with “Check oil level at idle while in neutral. Use synthetic Dextron III”.

Note: Optional left side tube mounting is available, contact sales account manager for additional information.

Note: Dipstick mounting location shown below.

Dipstick/Fill Tube Location 1 -5/8 - 12 UN - 2A For SAE O-Ring Fitting (OEM Supplied)

23

Installation Requirements

1.

Installation Requirements

UltraShift AW3 WetClutch Dipstick Information

Cold "FULL" Level

35.6 [ 1.40 ] 64.0 [ 2.52] 15.2 [ 0.60 ]

Cold "ADD" Level Approx. 1 quart

Note: The first section of the dipstick tube must remain vertical for a minimum of 2.5 inches from the end of the fill tube.

Note: A ball end or some equivalent is recommended on the dipstick to prevent interference with tube mounting.

Note: All fluid levels are measured with the system operating in neutral with the transmission oil temperature between 60° F [-18°C] and 120° F [49°C].

24

Installation Requirements

Air Supply Requirements Heavy Duty 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 [4.481] bar.

3.

A minimum of 1/4” i.d. [.635 cm] 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 vehicle 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 introducing moisture into the airline.

6.

Care should be used when routing the air supply to avoid kinks and close contact to heat sources.

7.

The transmission air supply must be connected to the air filter/regulator mounted on the range cylinder cover.

Note: The air filter/regulator must not be removed during installation.

8.

Air additives such, as alcohol devices should not be permitted to enter the transmission air supply. Additives could cause damage to air system components, which could lead to degraded transmission performance.

Air Drying SERVICE TANK

Compressor Do not tie wrap air line to wire harness on transmission

25

Installation Requirements

1.

Installation Requirements

Engine Retarder Requirements Heavy-Duty An engine retarder (compression or exhaust) is required on AutoShift 10 and 18-Speed and 13-Speed UltraShift transmissions. It is recommended on the 10-Speed UltraShift transmission.

1.

The transmission sends J-1939 Torque/Speed Control 1 (TSC1) torque control commands to the engine retarder (compression or exhaust) when deceleration assistance during a shift is required. The transmission automatically detects the retarder source address (compression or exhaust) and addresses the TSC1 accordingly. If both compression and exhaust are present, the transmission will address exhaust only.

2.

The engine retarder shall respond to TSC1 control commands as indicated by Actual Retarder Percent torque within 50 msec of the TSC1 command.

3.

The engine retarder shall respond to TSC1 commands regardless of the status of the engine brake control switches on the dash.

4.

The engine retarder shall affect the engine deceleration rate within 250 msec to 300 msec of the request. Longer response times will adversely affect the transmission’s upshift capabilities on a grade and may limit applications to grades 8% and lower. Response times greater the 500 msec are not acceptable.

5.

The engine retarder shall respond to zero percent torque control command by turning off the engine brake within 250 msec. Longer delay times to turn off may cause harsh gear engagements and loss of vehicle speed.

6.

The engine shall have a minimum deceleration rate of 1000 rpm/sec with the engine retarder at 100%. The engine is disengaged from the driveline and is virtually unloaded.

7.

The recommended practice is for the exhaust brake on/off switches to be wired in the engine ECM separately from the exhaust brake solenoid. Failure to comply with this recommended practice can cause Eaton AutoShift/UltraShift transmissions to miss shifts when the exhaust brake is required. For more information contact Eaton Application Engineering and refer to the J-1939 Engine Requirements for Eaton AutomatedTransmissions.

Medium-Duty

26

1.

The transmission sends J-1939 Torque/Speed Control 1 (TSC1) torque control commands to the engine retarder (compression or exhaust) when deceleration assistance during a shift is required. The transmission automatically detects the retarder source address (compression or exhaust) and addresses the TSC1 accordingly. If both compression and exhaust are present, the transmission will address exhaust only.

2.

The engine retarder shall respond to TSC1 control commands as indicated by Actual Retarder Percent torque within 50 msec of the TSC1 command.

3.

The engine retarder shall respond to TSC1 commands regardless of the status of the engine brake control switches on the dash.

4.

The engine retarder shall respond to zero percent torque control command by turning off the engine brake within 250 msec. Longer delay times to turn off may cause harsh gear engagements and loss of vehicle speed.

5.

The recommended practice is for the exhaust brake on/off switches to be wired in the engine ECM separately from the exhaust brake solenoid. Failure to comply with this recommended practice can cause Eaton AutoShift/UltraShift transmissions to miss shifts when the exhaust brake is required. For more information contact Eaton Application Engineering and refer to the J-1939 Engine Requirements for Eaton AutomatedTransmissions.

Installation Requirements

Eaton Shift Console Space Requirements 22.86 [0.900] 39.75 [1.565]

172.72 [6.800] 32.21 [1.268]

38.10 [1.500]

165.10 [6.500]

76.20 [3.000] 2X #8-32 UNC

57.28 [2.255]

Installation Requirements

101.98 [4.015]

10.16 [0.400]

83.82 [3.300]

22.23 [0.875] 27.00 [1.063]

R N SERVICE

PANEL CUT OUT DIMENSIONS

77.72 [3.06]

D MANUAL

SHIFT

LOW EATON FULLER TRANSMISSIONS

166.62 [6.56]

4X R.10 MAX

Mating Connector Information 1.

Packard

30-way

2.

Body

12048455

3.

Terminal

12103881

4.

Packard connector to Push Button Controller torque is 7.1 - 13.3 lbs. in. [0.8 - 1.5 N•m]

5.

Push Button Shift Controller Backing Plate Mounting Nuts torque are 14 - 16 lbs. in. [1.58 - 1.80 N•m]

27

Installation Requirements

OEM Cable Shift Lever with Park (OEM Provided) Note: The shifter shown below is a generic view of a cable shifter. The OEM is responsible for their own cable shifters. Eaton does not provide cable shifters.

28

Installation Requirements

Installation Requirements

6.0 [0.24]

19.3 [0.76]

32.4 21.6 33.9

10.8

Shift Cable Orientation To Lever When In Neutral

5.0 10.8

14.4

7.950 - 8.200 [0.3130 - 0.3228]

74.0 [2.91] 27.5 [1.08] 70.0 [2.76] 102.0 [4.02]

2 x M12 x 1.75-6H 22.4 [0.88]

M12 x 1.75-6H 16.0 [0.63]

Shift Mechanism Design Notes 1.

All shift mechanism designs must be approved by Eaton engineering.

2.

Shift lever must provide a brake pedal interlock to move from the park position.

3.

Shift lever must lock in positions P, R, N, and D.

4.

All adjustments must be made with the lever and transmission in the Neutral (N) position.

5.

Shift lever must be back lighted to illuminate the selected mode.

6.

Shift cable routing not to touch TECU.

29

Installation Requirements

Flywheel/Drive Coupler UltraShift AW3 The flywheel and Torsional Coupler assembly for the UltraShift AW3 must be an Eaton approved design and must be installed per the appropriate Eaton or Engine OEM specifications.

A separate bolt on Drive Coupler, is used with the Eaton UltraShift AW3 transmission The flywheel must be an Eaton approved 14-inch flat design. (Same flywheel used with a 14-inch Solo clutch)

1.

Handle the Drive Coupler carefully to avoid damage to the mating surfaces.

2.

The installed flywheel must meet the OEM specifications for concentricity. Refer to engine specifications for runout limits.

3.

Install the flywheel onto the engine crankshaft, using the hardware and mounting specifications of the engine manufacture.

4.

Install the Input shaft pilot bearing.

5.

The Drive Coupler alignment tool must be used when installing the Drive Coupler. Contact your Eaton Liaison Engineer for alignment tool print.

6.

Install the Drive Coupler using (12) Hex head capscrews with lock washers 3/8-16 X 1¼ SAE grade 5 minimum. Torque to 35 - 40 lbs. ft. [47 - 55 N•m].

Flywheel Coupler

Alignment Shaft

30

Installation Requirements

Medium Duty DM Clutch Installation The DM clutch operates in a normally released condition. Therefore, when the clutch is bolted to the flywheel there will be no plate load to hold the driven discs in place.

1.

Un-locked Position

Locked Position

2.

Install two guide studs into two of the clutch mounting holes. It is recommended to use holes at the three o'clock and nine o'clock positions. Be sure to use guide studs to ensure proper alignment of the clutch assembly to the flywheel.

3.

Use a lifting device to pick up the clutch. Install the alignment shaft through the cover assembly and driven disc.

4.

Slide the clutch assembly over the guide studs and start six of the clutch mounting bolts. Note: Position the clutch with the balance arrow up as close to vertical as practical (see Medium Duty Clutch picture on next page). Start at the lower left when tightening the clutch mounting bolts. Remove the guide studs and install the two remaining mounting bolts.

Tighten the clutch mounting bolts in a crossing pattern as on any other clutch and torque to 30 - 35 lbs. ft. [41 - 47 N•m].

5.

Remove the alignment shaft.

31

Installation Requirements

The clutch should be shipped with the clutch locking device engaged. Verify that it is engaged before bolting the clutch to the engine. To engage the locking device, simultaneously push in on the locking device return spring and turn the lock approximately 1/3 of a turn in the counter clockwise direction.

Installation Requirements

Medium Duty DM Clutch 3/8 x 2.25 x 16 coarse thread Grade 5 or better Torque to 30 - 35 lbs. ft. [41 - 47 N•m] in a criss cross sequence

2

6

LOCKING DEVICE RETURN SPRING (LOCKED POSITION)

7

8

LOCKING DEVICE

3 4

4 x 5/16-18 UNC JACK SCREW LOCATIONS

5 1 Note: The DM clutch is only intended to work with an Eaton UltraShift transmission.

32

Installation Requirements

Heavy Duty DM Clutch Installation The DM clutch operates in a normally released condition. Therefore, when the clutch is bolted to the flywheel there will be no plate load to hold the driven discs in place.

1.

Un-locked Position

Locked Position

2.

Install two guide studs into two of the clutch mounting holes. It is recommended to use holes at the three o'clock and nine o'clock positions. Be sure to use guide studs to ensure proper alignment of the clutch assembly to the flywheel.

3.

Use a lifting device to pick up the clutch. Note that the intermediate plate is bolted to the cover assembly and the rear driven disc is in place between the pressure plate and intermediate plate. DO NOT unbolt the intermediate plate from the cover assembly. With an alignment shaft through the cover assembly and the rear disc, install the front driven disc on the alignment shaft.

4.

Slide the clutch assembly over the guide studs and start six of the clutch mounting bolts. Start at the lower left when tightening the clutch mounting bolts. This will ensure that the clutch is properly pulled into the flywheel pilot. Failure to do this could result in improper piloting of the clutch and cause clutch damage. Remove the guide studs and install the two remaining mounting bolts. Tighten the clutch mounting bolts in a crossing pattern as on any other clutch and torque to 40 - 50 lbs. ft. [54 - 68 N•m].

5.

Remove the alignment shaft.

Note: The DM clutch is only intended to work with an Eaton UltraShift transmission.

33

Installation Requirements

The clutch should be shipped with the clutch locking device engaged. Verify that it is engaged before bolting the clutch to the engine. To engage the locking device, simultaneously push in on the locking device return spring and turn the lock approximately 1/3 of a turn in the counter clockwise direction.

Installation Requirements

Heavy Duty DM Clutch 7/16 x 2.25 x 14 course thread Grade 5 or better Torque to 40 - 50 lbs. ft. [54 - 68 N•m] in a criss cross sequence

2

LOCKING DEVICE RETURN SPRING (LOCKED POSITION)

6

4 x 5/16-18 UNC JACK SCREW LOCATIONS

LOCKING DEVICE

7

3

4

8

5

1

Note: The DM clutch is only intended to work with an Eaton UltraShift transmission.

34

Installation Requirements

Transmission Mounting Requirements Handling Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components.

1.

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

Installation Requirements

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 the sensor or sensor lock nut to 35 lb- ft [47 N•m], (3/416 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, or replace a rear bearing cover, output shaft seal, or output yoke/flange refer to the appropriate service manual on the roadranger website.

Mounting Transmission to Engine Use the two transmission lifting eyes provided. The lifting eye position must not be changed on the transmission. Do not remove the Electric Shifter at any time.

Note: For lifting eye and sensor retaining bolt locations. [see page 90] These bolts can not be used for brackets or for any other purpose.

4.

Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs.

5.

Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure the engine flywheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of damage before installation.

6.

Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmission must be in gear in order to rotate the input shaft by turning the output shaft/yoke. The transmission will automatically reset to the neutral position as soon as the vehicle is powered up (key switched on). In the event that the transmission is not received in gear, the input shaft will have to be manually indexed to mate up with the clutch splines.

Note: DRIVE SHAFT INSTALLATION- since the transmission is in gear until the vehicle is powered up with the key switch, use a Pull-To-Neutral-Box to disengage the transmission or rotate the axles to align the transmission prop shaft.[see page 123] 7.

Adjust the lift chain or transmission jack to obtain the same relative angle as the engine. The face of the engine flywheel housing and the face of the transmission clutch housing must be parallel during installation. If the transmission is properly aligned and the clutch is installed properly, very little force is required to slide the input shaft through the clutch and into the pilot bearing.

8.

If interference is encountered, move the transmission away from the engine to investigate the cause. The use of excessive force to overcome misalignment may cause damage to the transmission input shaft and the clutch.

9.

Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines.

10. 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.

35

Installation Requirements

11. Tighten four capscrews at 90° intervals around the clutch housing, then tighten the remaining transmission mounting capscrews using the recommended torque specifications.

Note: UltraShift Gen 3 AW3 transmissions use a longer M10 x 1-3/4 capscrew to mount the transmission to the engine.

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.

Note: UltraShift Gen 3 AW3 requires the use of an input shaft rotating tool. Contact your Eaton Liaison Engineer for alignment tool print

Using Rear Supports The OEM is responsible to determine if a rear support is required for each application.

36

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.

The OEM is responsible for rear mount design.

4.

Refer to OEM for rear or nodal mount fastener torque specifications.

5.

For HVP rear mount support contact Eaton Enigneering.

Electrical Requirements

Cable All wiring installation shall conform to Federal Motor Carrier Safety Administration Regulations Sections 393.27 Wiring specifications; 393.28 Wiring to be protected; 393.29 Grounds; 393.31 Overload protective devices; and 393.33 Wiring, installation.

The cable for the Deutsch connector shall be: •

16 GXL max 18 TXL min for Communication and control wires

•

12 GXL for Power Supply wires

•

12 GXL or 14 SXL for V-Ignition wires

These sizes are requirements for proper connector sealing and current carrying capacity.

SAE Wire

SAE Wire

Nominal Outside Diameter (mm)

Nominal Outside Diameter Inch

Size mm²

Size No.

TXL

TXL

0.8

18

1.98

2.39

2.72

0.08

0.09

0.11

1

16

2.24

2.59

3.05

0.09

0.10

0.12

2

14

2.62

2.97

3.58

0.10

0.12

0.14

3

12

3.25

3.63

4.14

0.13

0.14

0.16

5

10

3.96

4.45

4.95

0.16

0.18

0.20

GXL

SXL

GXL

SXL

Electrical Requirements

Cable Connector (Deutsch) - DRC26-38S01-P017 Seal Range (mm) / (in)

Contact Size

1.02 - 2.41 /.040 .095

20

3.40 - 4.95 /.134 .195 3.40 - 4.95 /.134 .195

Description

Cable Diameter MIn (mm²)

Cable Diameter Max (mm²)

Signal

1.02

2.41

16

16

NR

12

Power

3.40

4.95

NR

12

NR

12

V-Ignition

3.40

4.95

NR

12

14

Back Shell (Deutsch)

*Low Profile Backshell (Deutsch)

Part Number

0528-004-3805

0528-005-3805

Conduit/OEM

Packard

Packard

Conduit P/N

*(R-69246 round) Convoluted Tubing; Size 13 mm [.500]; 125° C or higher temperature rating

(R-72506 profile) *(R-69246 round) Convoluted Tubing; Size 13 mm [.500]; 125° C or higher temperature rating

TXL

GXL

SXL

Note: * Eaton recommended component

37

Electrical Requirements

RECOMMENDED BEND RADIUS (6 X HARNESS DIAMETER) Inch

Metric (mm)

Diameter

Bend Radius

Diameter

Bend Radius

3/16 (0.188)

1.1

5

29

1/4 (0.250)

1.5

6

38

3/8 (0.375)

2.3

10

57

1/2 (0.500)

3.0

13

76

5/8 (0.625)

3.8

16

95

3/4 (0.750)

4.5

19

114

1/1 (1.000)

6.0

25

152

Contact Lubrication Manufacturer: Nye Lubricants Material: NyoGel 760G Eaton Part Number: 5564527 (service, 2 CC Foil), 5564528 (service, 30 CC Syringe) Bosch Part Number: N28 FT7020-005 Ford: WSB-M1C239-A GM: 9986087 DaimlerChrysler: MS-9469

Contact Lubrication Application WARNING

If a connection to the harness or ECU is required before vehicle installation, Eaton requires the use of a connector with a spring loaded contact rather than a standard mating connector. The spring loaded contact is intended to make the electrical connection with the tip of the terminal without touching the mating surface. This will protect the terminal plating, the NyoGel 760G™ and retain the original durability and reliability of the connector system.

Eaton highly recommends the use of (NyoGel 760G) on all electrical contacts and the amount used. For further information contact your Eaton OEM Engineering Support Group.

The preferred method of application is to use a metered dispensing mechanism that places the material on the socket of the connector. It is also preferred that the material be placed immediately prior to connector mating to reduce the probability of contamination.

The recommended minimum material volume for the MetricPack 150 speed sensor contact is .004 CC per socket.

The recommended minimum material volume for the Deutsch size 20 contact is .004 CC per socket.

The recommended minimum material volume for the Deutsch size 12 contact is .024 CC per socket.

38

Electrical Requirements

Transmission ECU Jackscrew Torque Connector jackscrew torque shall be 25 +/- 3 lbs. in. (2.82 +/- .33 N•m).

The Nyogel 760G material shall not be applied to the Transmission ECU 38-Way (Vehicle Interface) connector jackscrew. No antiseize, lubricating, or other foreign compound shall be applied to the connector jackscrew threads. The use of such compounds may affect jackscrew torque and prevent proper sealing of the connector.

Vehicle Speed Sensor-VSS (Heavy Duty Only) Eaton recommends that the OEM utilize the provided bracket near the vehicle speed sensor to anchor their VSS harness to. The bracket is designed to accommodate both the transmission harness and the OEM VSS harness.

Conductor Material Conducting material shall be stranded bare copper wire.

Electrical Requirements

Connectors Connectors shall be designed for use in the heavy-duty industry conforming to SAE J-2030 and J-1455.

Terminals Terminals shall be sized for the correct current capacity of the circuit as stated by the manufacturer.

Terminals shall be plated with tin, nickel, gold, etc. Mating terminals shall be plated with the same material. Gold plated terminals shall be required in 5 volt dry circuits. Beryllium Copper or equivalent should be used as a base material.

Low Power Pins (size 20): Communication and Control Wires SAE J1128 0.8 mm² wire (No. 18) TXL min, or (No. 16) GXL max Mating socket: Deutsch Stamped and Formed, Gold Plated, #PN 1062-20-0244 Hand crimping tool - DTT-20-02 High Power Pins (size 12): Power Supply Wires SAE J1128 2.0 mm² wire (No. 14) SXL SAE J1128 3.0 mm² wire (No. 12) GXL Mating socket: Deutsch Stamped and Formed, Nickel Plated, #PN 1062-12-0166 Hand crimping tool - DTT-12-00 Note: For Park sensor terminal contact Eaton Engineering.‘ Note: Recommended wire strip length is .175 inch ± .025.

Note: For tools contact Deutsch at 951-765-2250.

Ring Terminals Terminals such as ring, bullet, spade, ect., shall be sized for the correct current capacity of the circuit as stated by the manufacturer. Terminals shall be plated and non-insulated. Sleeves shall be insulated with a double wall shrink tubing.

Sealing Dielectric grease over the top of the ring is recommended.

39

Electrical Requirements

Convoluted Conduit Convoluted conduit must have an operating temperature of at least 257°F (125°C).

Braided Loom (Mesh) (Recommended) Coverage: A minimum of 10, maximum of 12 picks per inch. The braid shall be woven so as to produce a tight non-slip covering over the cables. The braid shall be heat-sealed to prevent unraveling. Braid must have a minimum service temperature of 280°F (138°C).

Insulating Sleeves Sleeves shall be constructed of a heat shrinkable, irradiated, adhesive lined, semi-rigid polyolefin. The color shall be black. Typical shrinkage shall be 50% in diameter when exposed to heat (302°F) (150°C).

Tape Adhesive tape for harness forming and spot taping shall be TESA Black Cloth Tape P/N 51006 which is supplied by Great Lakes Tape Company. The tape shall have a pressure sensitive adhesive coating on one side.

Crimping The crimp shall be applied with a tool specified by the manufacturer of the terminal.

Terminals shall be applied according to terminal manufacturer’s specifications.

Stripping An allowable maximum of one strand may be cut on 16 gauge or larger, no strands on 18 gauge, and no strands on 20 gauge in the crimp area.

Soldering No terminals shall be soldered.

Splice Splices are not allowed.

Twisted Cables 2 conductor cables shall have 12 twists/foot [.30 meters]. (16 and 18 gage cable only) •

Twisted cable on the J1939 backbone can be size 16 TXL

•

Twisted cable into Deutsch DRC connector must be size 18 TXL min, or 16 GXL max

All cable lengths to multi-cavity connectors shall be cut and dressed to ensure no undue stress is on an individual wire after insertion into the connector. After insertion, all terminals shall be checked for retention.

40

OEM

Terminating resistor

38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1

30 AMP fuse

Battery power (Non-switched power) run to Battery

1 1

8 8

2 2

6 6

5 7 5 7

_

GND

+

Engine ECM

J-1939 High

30 87 86 85

A

H

D

J

C

9-way

E

B

Start enable relay

Run to start signal from igntion switch

C D B F G A

G

F

For transmission diagnostics per SAE Standard

Run to starter solenoid

J-1939 Low Ignition Key Switch Runs to main power lead that + Battery feeds the ignition bus (OEM responsible for overcurrent protection on this line) J-1587 data link

Terminating resistor

10 AMP fuse

10 AMP only manual resetting circuit breaker

Dimmer control input Back side of gauges Dash lights

Or

Shield termination

J-1939/11 data link (OEM supplied)

Bulkhead connector located at firewall

3 4 3 4

Electrical Requirements

Transmission Controller (ECU)

Electrical Requirements

Wiring Diagrams OEM Responsibility

AutoShift Gen 3 and UltraShift AW3 with Eaton Shift Lever

41

Transmission Controller (ECU)

42 OEM

Terminating resistor

38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1

30 AMP fuse

Battery power (Non-switched power) run to Battery

6 5 7 6 5 7

or

GND

+

_

Shield termination

J-1939/11 data link (OEM supplied)

10 AMP fuse

87a

87

85

86

30

Engine ECM

Ignition Interrupt relay

+ Battery

30 87 86 85

A

H

D

J

C

9-way

E

B

Start enable relay

Run to start signal from igntion switch

C D B F G A

G

F

For transmission diagnostics per SAE Standard

Run to starter solenoid

J-1939 Low

J-1939 High

J-1587 data link

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

Terminating resistor

* Run to ignition input on Engine ECM

10 AMP fuse

10 AMP only manual resetting circuit breaker

Back side of gauges Dash lights

Dimmer control input

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

Bulkhead connector located at firewall

3 4 1 8 2 3 4 1 8 2

Electrical Requirements

UltraShift Gen 3 DM3 with Eaton Shift Lever

Transmission Controller (ECU)

OEM

38 36 27 28 25 31 35 10 11 26 32 4 3 2 1

Terminating resistor

30 AMP fuse

Battery power (Non-switched power) run to Battery

F1 J3

C1

B3

_

GND

+

Or

Engine ECM

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

Terminating resistor

10 AMP fuse

10 AMP only manual resetting circuit breaker

Dimmer control input Back side of gauges Dash lights

Shield termination

J-1939/11 data link (OEM supplied)

Bulkhead connector located at firewall

F2

Push Button Control 30-way connector

Electrical Requirements

Push Button Shift Control

30 87 86 85

Run to starter solenoid

J-1587 data link

+ Battery

J-1939 Low

J-1939 High

A

H

D

J

C

9-way

E

B

Start enable relay

Run to start signal from igntion switch

C D B F G A

G

F

For transmission diagnostics

Electrical Requirements

AutoShift Gen 3 and UltraShift AW3 with Eaton Push Button Shifter

43

Transmission Controller (ECU)

44

OEM

Terminating resistor

38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1

30 AMP fuse

Battery power (Non-switched power) run to Battery

F1 J3

C1

B3

Or

_

GND

+

Shield termination

J-1939/11 data link (OEM supplied)

10 AMP fuse

87a

87

85

86

30

Engine ECM

J-1939 High

Ignition Interrupt relay

30 87 86 85

A

H

D

J

C

9-way

E

B

Start enable relay

Run to start signal from igntion switch

C D B F G A

G

F

For transmission diagnostics per SAE Standard

Run to starter solenoid

J-1939 Low Ignition Key Switch + Battery Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line) J-1587 data link

Terminating resistor

* Run to ignition input on Engine ECM

10 AMP fuse

10 AMP manual resetting circuit breaker

Back side of gauges Dash lights

Dimmer control input

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

Bulkhead connector located at firewall

F2

Push Button Control 30-way connector

Push Button Shift Control

Electrical Requirements

UltraShift Gen 3 DM3 with Eaton Push Button Shifter

Transmission Controller (ECU)

OEM

Terminating resistor

35 10 11 26 32 4 22 21 20 3 2 1

31 15 16 17

38 36

30 AMP fuse

Battery power (Non-switched power) run to Battery

1

2

4 3 1

Or

GND

+

_

Shield termination

J-1939/11 data link (OEM supplied)

10 AMP fuse

Engine ECM

Ignition Interrupt relay

30 87 86 85

A

H

D

J

C

9-way

E

B

Start enable relay

Run to start signal from igntion switch

C D B F G A

G

F

For transmission diagnostics per SAE Standard

Run to starter solenoid

J-1939 Low

J-1939 High Ignition Key Switch Runs to main power lead that + Battery feeds the ignition bus (OEM responsible for overcurrent protection on this line) J-1587 data link

Terminating resistor

* Run to ignition input on Engine ECM

87a

87

85

86

30

10 AMP fuse

10 AMP only manual resetting circuit breaker

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

Bulkhead connector located at firewall

2

4

Electrical Requirements

4-Pin Park Pawl Actuator Connector (DTM04-4P) 3

Electrical Requirements

UltraShift Gen 3 HV-P with Eaton Park Shifter

45

Installation Requirements

Eaton Shift Lever and Tower Space Requirements ( 11.0˚

)

( 31.0˚

)

NEUTRAL POSITION REVERSE GEAR POSITION

LOW GEAR POSITION

( 259.6 [ 10.22 ( 32.3 [ 1.27

) ]

) ( 22.6 ) [ .89 ]

]

(

13.2 [.52]

4305447

)

2X 691900

( 89.2 [ 3.51

) ]

16.00 [ .630

4X M6x1-6H INSERTS ARE ALLOWED 0.25 [.010] ADDITIONAL TOLERANCE

]

4X X 8-163 184.15-209.55 [7.250-8.250]

4

111.25 [ 4.380 ( 123.70 [ 4.870

]

( 58.2 [ 2.29

) ]

67.6 MAX [2.66]

Mating Connector Information QTY 1 7 1 1

46

Deutsch Part Number DTM06-08SA 1062-20-0144 WM-8S 0413-204-2005

Description Housing Contact - Pin Wedge Lock Cavity Plug

) ]

Installation Requirements

142.04 [5.592]

165.1 [6.50] 2x 3.81 [.150]

11.56 [.455]

54.10 [2.130]

Installation Requirements

559.3 [22.02]

241.3 [9.50] 133.10 [5.240] 8x

7.92 [.312]

47

Installation Requirements

Eaton HV Cable Shift Lever With Park (OEM Provided)

Mating Connector Information QTY 1 4 1

48

Deutsch Part Number DTM06-4S 0462-201-2031 WM-4S

Description Housing Contact - Socket Wedge Lock

Electrical Requirements

Typical System with Eaton Push Button Push Button Shift Control

Push Button Control 30-way connector C2

Transmission ECU Connector (Vehicle Interface)

Dimmer control input

F2 F1 J3 C1 B3

J1 27 28 25 31

Bulkhead connector located at firewall

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

Electrical Requirements

Front View Transmission ECU Connector (Vehicle Interface)

Front View Shift Control (30-Way Connector) 38 22

21 36

F1

E1

D1

G2

F2

E2

D2

G3

F3

E3

D3

K1

J1

H1

G1

K2

J2

H2

K3

J3

H3

C1

B1

A1

C2

B2

A2

C3

B3

A3

Packard Connector 12048455 Terminal 12103881 Plug 12034413

Note: Cinch is an equivalent.

When the Eaton Push Button Shift Control is used the CAN (Control Area Network communications link between the Shift Control and the Transmission Controller) must be a J-1939/15 twisted pair cable.

FROM

TO

J1-27

C2-F2

HIL LOW (Proprietary CAN)

J1-28

C2-F1

HIL HIGH (Proprietary CAN)

J1-25

C2-J3

Shift Control Power Minus

J1-31

C2-C1

Shift Control Power Plus

C2-B3

DESCRIPTION

Dimmer Control Input

49

Electrical Requirements

Typical System with Eaton Shift Lever

3 4 3 4

1 1

8 8

2 2

6 6

5 7 5 7

C2

Transmission ECU Connector (Vehicle Interface) J1

Dimmer control input Back side of gauges Dash lights

25 31 15 16 17 23

Bulkhead connector located at firewall Front View Transmission ECU Connector (Vehicle Interface)

37 14

13

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

35

50

FROM

TO

DESCRIPTION

J1-15

C2-1

Shift Control Input 2 (Mode Auto)

J1-17

C2-2

Shift Control Input (Mode Common)

J1-25

C2-3

Shift Control Power Minus

J1-31

C2-4

Shift Control Power Plus

C2-5

Dash Lights

J1-23

C2-6

Service Light Output

J1-16

C2-8

Shift Control Input 1 (Mode Manual)

C2-7

No Connection

38 22

21 36

Electrical Requirements

Typical System with Eaton Park Shift Lever 4-Pin Park Pawl Actuator Connector (DTM06-4S) 3 2 1 4

Transmission ECU Connector (Vehicle Interface)

4

3

1

2

F2

15 16 17 31

Electrical Requirements

Front View Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 22

21 36

FROM

TO

DESCRIPTION

J1-15

F2-4

Shift Control Input 2

J1-16

F2-3

Shift Control Input 1

J1-17

F2-1

Shift Control Input Common

J1-31

F3-2

Shift Control Power Positive

51

Electrical Requirements

Typical System with OEM Shift Lever OEM supplied Shift Lever must have gated positions per Eaton engineering specification. If an OEM supplied Resistive Ladder type Shift Lever is used in conjunction with a J-1939 gear display, Eaton recommends the service lamp connector is located close to the 6 or 9-pin diagnostic connector.

OEM Shift Lever

Transmission ECU Connector (Vehicle Interface)

B

A

C

B

A

C

15 16 17 23

F2 F3 Service Lamp Connector 2-Way Connector OEM can select

FROM

TO

J1-15

F2-B

Shift Control Input (Mode Auto)

J1-16

F2-A

Shift Control Input (Mode Manual)

J1-17

F2-C

Shift Control Input (Mode Common)

J1-23

F3-A

Service Lamp Output

F3-B

52

DESCRIPTION

Ground

Electrical Requirements

Typical System with OEM J-1939 Shift Input Device

OEM J-1939 Shift Device Transmission ECU Connector (Vehicle Interface)

Bulkhead connector located at firewall

J1

16 17

Electrical Requirements

J-1939 Battery Power (Non-switched power run to Battery)

Ground

Switched Power Front View Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 21

22 36

FROM

TO

DESCRIPTION

J1-16

Connector C2

Shift Control Input (Neutral Request Signal)

J1-17

Connector C2

Shift Control Input (Neutral Request Return)

OEM

Connector C2

Shift Control Power Minus (Ground)

OEM

Connector C2

Shift Control Power Plus (Ignition)

OEM

Connector C2

Shift Control Power Plus (Battery)

OEM

Connector C2

J-1939 High

OEM

Connector C2

J-1939 Low

OEM

Connector C2

J-1939 Shield

53

Electrical Requirements

Power Harness Transmission ECU Power Harness J5 connects to the (-) Ground side of the Main Battery Source

J6 connects to the (+) side of the Main Battery Source J6

J5

OEM responsible for overcurrent protection on this line J8

J9

J7

J7 Delphi Metri Pak 2 Pin Fuse Holder Connector Assembly 12033769 Terminal 12033769 Cable Seal 12040972 J8 Cover

12033731

J9

30 AMP Fuse

J1

Transmission ECU Connector (Vehicle Interface)

54

FROM

TO

WIRE DESCRIPTION

J5

J1-36

Ground

J6

J7-B

Battery

J7 A

J1-38

Fused Battery

Electrical Requirements

Preferred +12 Volt Connections STARTER BATTERY PLUS 2 GEN 3 ECU BATTERY PLUS

+

+

+

+

STARTER BATTERY PLUS 1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

-

-

-

-

STARTER BATTERY M INUS 1

STARTER BATTERY M INUS 2

TWO BATTERY BANKS - TWO BATTERIES PER BANK - DUAL JUMPERS TO STARTER BATTERIES ARE CONNECTED IN PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED BY BATTERY CLOSEST TO STARTER (BOTH PLUS AND MINUS)

Electrical Requirements

CAB BATTERY PLUS

GEN 3 ECU BATTERY PLUS

STARTER BATTERY PLUS 1

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

STARTER BATTERY M INUS 1

-

-

-

-

ONE BATTERY BANK - FOUR BATTERIES BATTERIES ARE CONNECTED IN PARALLEL. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS)

CAB BATTERY PLUS

MAG RELAY

GEN 3 ECU BATTERY PLUS

+

+

+

+

STARTER BATTERY PLUS 1

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

-

-

-

-

STARTER BATTERY M INUS 1

TWO BATTERY BANKS - TWO BATTERIES PER BANK WITH DISCONNECT BATTERIES ARE CONNECTED IN PARALLEL BY PAIRS - DISCONNECT FOR CAB AND VEHICLE START DISCONNECTED PAIR PROVIDES "DEEP DISCHARGE" CAB COMFORT AND ENTERTAINMENT CAPABILITY. GEN 3 POWER SUPPLIED FROM BATTERY SET CLOSEST TO STARTER AND COMMON TO CAB POWER

55

Electrical Requirements

GEN 3 ECU BATTERY MINUS GEN 3 ECU BATTERY PLUS

+

+

+

+

STARTER BATTERY PLUS

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

-

-

-

-

STARTER BATTERY MINUS

BATTERY M INUS

VEHICLE BATTERY MINUS

TWO BATTERY BANKS - BATTERY NEGATIVE DISCONNECT SWITCH BATTERIES ARE DISCONNECTED AT POWER DOWN WHEN VEHICLE STORED INSIDE. GEN 3 POWE R SUPPLIED FROM BATTERY CLOSEST TO THE STARTER. NEGATIVE CONNECTION AT POINT OF VEHICLE CABLE CONNECTION TO DISCONNECT SWITCH

GEN 3 ECU BATTERY PLUS

POWER DISTRIBUTION MODULE (POWER BUS AND OVER CURRENT DEVICES) STARTER BATTERY PLUS

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

STARTER BATTERY MINUS

-

-

-

-

POWER DISTRIBUTION MODULE BATTERIES ARE CONNECTED IN PARALLEL, POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. CABLES SIZE AND LENGTH OPTIMIZED FOR LOW VOLTAGE DROP

CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS

Starter Battery Plus

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

STARTER

-

-

STARTER BATTERY MINUS

GEN 3 ECU BATTERY MINUS

STARTER BATTERY CONNECTION GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.

CAB BATTERY PLUS

GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS 1

-

-

ONE BATTERY BANK - TWO BATTERIES BATTERIES ARE CONNECTED IN PARALLEL. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS)

56

Electrical Requirements

Preferred +24 Volt Connections

STARTER BATTERY PLUS 2

STARTER BATTERY PLUS 1 GEN 3 ECU BATTERY PLUS

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

-

-

-

-

STARTER BATTERY MINUS 1

STARTER BATTERY MINUS 2

Electrical Requirements

TWO BATTERY BANKS - TWO BATTERIES IN SERIES PER BANK - DUAL JUMPERS TO STARTER BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED BY BATTERY CLOSEST TO STARTER (BOTH PLUS AND MINUS)

CAB BATTERY PLUS GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS 1

-

-

-

-

ONE BATTERY BANK - FOUR BATTERIES - ONE CABLE PAIR TO STARTER BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO STARTER WITH CAB POWER. (BOTH PLUS AND MINUS)

CAB BATTERY PLUS

GEN 3 ECU BATTERY PLUS STARTER BATTERY PLUS 1

MAG RELAY

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS

-

-

-

-

STARTER BATTERY MINUS 1

TWO BATTERY BANKS - TWO BATTERIES PER BANK WITH DISCONNECT BATTERIES ARE CONNECTED IN SERIES/PARALLEL BY PAIRS - DISCONNECT FOR CAB AND VEHICLE START - DISCONNECTED PAIR PROVIDES "DEEP DISCHARGE" CAB COMFORT AND ENTERTAINMENT CAPABILITY. GEN 3 POWER SUPPLIED FROM BATTERY SET CLOSEST TO STARTER AND COMMON TO CAB POWER

57

Electrical Requirements

GEN 3 ECU BATTERY MINUS GEN 3 ECU BATTERY PLUS

+

+

+

+

STARTER BATTERY PLUS

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

-

-

-

-

STARTER BATTERY MINUS VEHICLE BATTERY MINUS

BATTERY MINUS

TWO BATTERY BANKS - BATTERY NEGATIVE DISCONNECT SWITCH BATTERIES ARE DISCONNECTED AT POWER DOWN WHEN VEHICLE STORED INSIDE. GEN 3 POWER SUPPLIED FROM BATTERY CLOSEST TO THE STARTER. NEGATIVE CONNECTION AT POINT OF VEHICLE CABLE CONNECTION TO DISCONNECT SWITCH

GEN 3 ECU BATTERY PLUS

POWER DISTRIBUTION MODULE (POWER BUS AND OVER CURRENT DEVICES) STARTER BATTERY PLUS

+

+

+

+

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

BATTERY

12 VOLT

GEN 3 ECU BATTERY MINUS STARTER BATTERY MINUS

-

-

-

-

POWER DISTRIBUTION MODULE BATTERIES ARE CONNECTED IN SERIES/PARALLEL, POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER. CABLES SIZE AND LENGTH OPTIMIZED FOR LOW VOLTAGE DROP

CAB BATTERY PLUS STARTER BATTERY PLUS

GEN 3 ECU BATTERY PLUS

STARTER

GEN 3 ECU BATTERY MINUS

STARTER BATTERY MINUS

STARTER BATTERY CONNECTION GEN 3 POWER PLUS AND MINUS CONNECTED ON BATTERY CLOSEST TO THE STARTER.

58

Electrical Requirements

Ignition Circuit Detail Transmission ECU Ignition Circuit 10 AMP only Manual resetting circuit breaker

Transmission ECU Connector (Vehicle Interface)

10 AMP fuse

Or

Ignition Key Switch Run to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

J1 35

Electrical Requirements

Front View Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

FROM

TO

J1-35

VIGN

38 21

22 36

Note: Battery and Ignition power and ground to the TECU must not be switched off during the engine start process.

59

Electrical Requirements

J-1587 Data Link For Transmission Diagnostics J1939 High D

E

J1939 Low

F

C

A

B

J

G H

+ Battery

C

J1

D B

10 11

F G A

J1587 Data Link

9-way

Transmission ECU Connector (Vehicle Interface)

Front View Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 21

22 36

The diagnostic connector (6-pin required 9-pin recommended) must be easily accessible and mounted on the drivers side of the cab.

Note: SAE has one approved connector. Eaton recommends the Deutsch 9-pin.

FROM

60

TO 9-PIN

DESCRIPTION

J1-10

F

J-1587 +

J1-11

G

J-1587 -

__

B

BATTERY +

__

A

GROUND -

__

C

J-1939 HIGH

__

D

J-1939 LOW

Electrical Requirements

J-1939/15 Data Link Maximum 40 meter Length.

Maximum 3 meter stub length.

Note: The distance between the TECU and Engine ECU should be as short a possible.

Maximum 10 modules on segment.

Twisted pair (18 gauge) with 1 twist per inch.

120 Ohm terminating resistors must be used.

The third pin for shield is not used in ‘in-line’ and T-connectors.

The J-1939 (the communications link between the Transmission ECU and the Engine Controller ECM) must follow SAE J-1939 specifications for either J-1939/11 or J-1939/15.

Electrical Requirements

Other Modules

Transmission ECU

Engine ECU

J1 Terminating Resistor

Terminating Resistor

J-1939/15 data link (OEM supplied)

Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

FROM

TO

J1-2

B

J-1939 Low -

J1-3

A

J-1939 High +

38 21

22 36

DESCRIPTION

61

Electrical Requirements

J-1939/15 Data Link Specifications Recommended Cable Manufacturer

Cable Part Number

Champlain

J1939/15

Twisted Pair J1939 (-)

J1939 (+)

J1939 (+)

J1939 (-)

Ref.

Body

A

Round Yes

J-1939 (+) (PIN "A") Color

J-1939 (-) (PIN "B") Color

Yellow

Green

Signal Terminals (QTY)

Wedge

Function

DTM-06-2S

0462-201-2031 (2)

WM-2S

Through Connector

B

DTM-06-2S

0462-201-2031 (2)

WM-2SB

Stub Connector

C

DTM04-2P-P007

N/A

N/A

"T" Receptacle

D

DTM06-2S-EP10

N/A

WM-2SB

120 Ohm Termination

E

DTM04-2P

0460-202-2031 (2)

WM-2P

ECU Receptacle

G

DTM06-2S-EP10

N/A

WM-2SB

120 Ohm Termination

Transmission ECU

3.00 Meter Max Length

B

D

Other Modules

Engine ECU

3.00 Meter Max Length

B

B A

C

A

A C

A

40.00 Meter Max Length

62

C

D

Electrical Requirements

Dimmer Control Input Connection

3 4 3 4

1 1

8 8

2 2

6 6

C2

5 7 5 7

Dimmer control input

Electrical Requirements

Back side of gauges Dash lights Bulkhead connector located at firewall Push Button Shift Control

Push Button Control 30-way connector F2

Dimmer control input F1 J3

C1

B3

Back side of gauges Dash lights

Bulkhead connector located at firewall

Note: Connect VDASH to the dash lights. This input will dim the lights on the Shift Control when the lights are on. When VDASH input is off, the lights on the Shift Control will be on full.

Shift Control

FROM

TO

Cobra Lever

C2-5

VDASH

Push Button

B3

VDASH

63

Electrical Requirements

Typical Start Enable Circuit Startability must meet FMVSS Standard 102, Section 3.1.3: “The engine starter shall be inoperative when the transmission shift lever is in a forward or reverse direction position”.

26 32 4

J1

Run to starter solenoid Run to start signal from igntion switch

Transmission ECU Connector (Vehicle Interface)

Start enable relay

30 87 86 85

Front View Transmission ECU Connector (Vehicle Interface)

37 14

13 35

64

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 22

21 36

FROM PIN

TO RELAY PIN

DESCRIPTION

J1-32

86

START ENABLE RELAY COIL, POSITIVE

J1-26

87

START ENABLE LATCH

J1-4

85

START ENABLE RELAY COIL, NEGATIVE

Electrical Requirements

Typical Start Enable Circuit * Ignition Power (switched power) Run to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

Use Bosch: Relay : 0332-209-151 (+12 volt), 0332-204-203 (+24 volt) or equivalent

+BATT Mount : 3334-485-008 Terminal : 1901-355-917

ACC OFF IGNITION START

Start Enable Battery (32)

86

KEY SWITCH

30

Electrical Requirements

Relay Schematic

85

87a

87

Run to Starter Solenoid Relay

Start Enable Ground (4)

Start Enable Latch (26)

Front View

Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 21

22 36

FROM PIN

TO RELAY PIN

DESCRIPTION

J1-32

86

START ENABLE BATTERY

J1-26

87

START ENABLE LATCH

J1-4

85

START ENABLE GROUND

65

Electrical Requirements

Typical Ignition Interrupt Circuit (MEIIR) 10 AMP only manual resetting circuit breaker or

10 AMP fuse J1

* Ignition Key Switch Run to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

35

30

Transmission ECU Connector (Vehicle Interface)

22

86

21

85

20

87

Ignition Interrupt relay

87a

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

* Run to ignition input on Engine ECM

10 AMP fuse FRONT VIEW

Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 21

22 36

IMPORTANT

1. There must be no other systems in the ignition circuit between the MEIIR and the engine ECM. 2. If there are other systems in the ignition circuit between the ignition switch and the MEIIR, contact Eaton for guidance. * For Vehicle/Engine systems which use a vehicle system ECU, contact the Eaton OEM Engineering Support Group for installation schematics.

FROM TRANSMISSION ECM PIN

TO RELAY PIN

J1-21

85

MEIIR - MINUS

J1-20

87

MEIIR - CONTACT

30

VIGN

86

MEIIR - PLUS

J1-22

66

DESCRIPTION

Electrical Requirements

Typical Ignition Interrupt Circuit Use Bosch: Relay : 0332-209-151 (+12 volt), 0332-204-203 (+24 volt) or equivalent

Mount : 3334-485-008 Terminal : 1901-355-917

Run to Engine Controller Power

Run to Transmission ECU pin (22)

86

30

Electrical Requirements

Relay Schematic

85

87a

87

* Run to Engine ECM ignition input

Run to Transmission ECU pin (21)

Run to Transmission ECU pin (20)

FRONT VIEW

Transmission ECU Connector (Vehicle Interface)

37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38

FROM TRANSMISSION ECM PIN

TO RELAY PIN

J1-21

85

MEIIR - MINUS

J1-20

87

MEIIR - CONTACT

30

VIGN

86

MEIIR - PLUS

J1-22

22

21 36

DESCRIPTION

* For Vehicle/Engine systems which use a vehicle system ECU, contact the Eaton OEM Engineering Support Group for installation schematics.

67

Electrical Requirements

Vehicle Harness Routing Requirements Harness and in-line connectors shall be anchored to prevent free movement. An anchor point shall be no further than 6 in. [15.24 cm] (recommended 3 in. [7.62 cm]) from a connector. The length of an unanchored section of harness should be no more than 12 in. [30.48 cm].

Use tie wraps on harness covering only, not individual wires. Do not anchor harness with tie wraps in contact with wire insulation. Tie wraps shall not pull on the harness so that connector cable seals are distorted. Allow cable to exit connector body with out pulling on the connector. A bend radius of six times the harness diameter is recommended.

Recommended use of the fixed clip points on OEM harness - Fir trees, J-clips, P-clips.

Harness routing shall not interfere with oil fill plugs, sensor locations, or manufacturing fixtures.

Ensure that all connectors are fully mated and that latches are locked. All connector jackscrews must be properly torqued. To prevent cross threading start all capscrews and nuts by hand then use a DC torque driver.

All unused connectors require sealed mated connectors.

There should be nothing mounted to the TECU, brackets, mounting studs, or contacting the TECU case electrically or mechanically.

The transmission wire harness should not be tie wrapped to any cables or hoses. Anchor points on the transmission may be used as long as addition of cables or hoses do not interfere with the existing harness.

68

Electrical Requirements

AutoShift/UltraShift Heavy Duty Use for Vehicle Harness Tiedown These are NOT lifting eyes

Electrical Requirements

Use for Vehicle Harness Tiedown These are NOT lifting eyes

69

Electrical Requirements

UltraShift Medium Duty

Use for Harness Tiedown These are NOT lifting eyes

Use for Harness Tiedown These are NOT lifting eyes

70

Electrical Requirements

UltraShift Medium Duty with Park Pawl Use for harness tiedowns.

These are NOT lifting eyes.

Electrical Requirements

Use for harness tiedowns.

These are NOT lifting eyes.

71

Features

Outside Cab Features Eaton recommends the OEM provide a connector and wiring coming from the Transmission ECU 38-Way (Vehicle Interface) with the AW3 Auto Neutral and PTO wires installed.

Note: Connector used must be compatible with 18 TXL. Note: Must use a dedicated ground on return line.

Note: Refer to Cable section “See Terminals” for correct wire and terminal pin sizes for communication and control wires.[see page 39]

J1

Transmission ECU Connector (Vehicle Interface) 18

19

J4

72

Transmission ECU Connector (Vehicle Interface)

FROM

TO

Description

J1-18

J4

PTO Input

J1-19

J4

Auto Neutral Input (AW3)

Features

Power Take-Off “Split Shaft” PTO input must be a normally open switch. The switch must close to ground whenever the PTO is activated. This input (active when pin 18 is shorted to ground) activates the split shaft PTO mode of the transmission. This feature uses pin 18 of the transmission connector.

Note: The active signal will illuminate the “Mode” indicator only on the Eaton push button console when the transmission direct drive gear is engaged for split shaft PTO operation.

The transmission default mode for the pin 18 input is for countershaft PTO operation. Countershaft PTO operation is the default operating mode and no enabling of the countershaft PTO feature is required unless the (pushbutton console) change to “TECU” was previously programmed for split shaft PTO operation.

The input signal wire for the PTO must be isolated from other PTO related circuits.

The ground connection must be isolated from local power device ground returns. Frame rail ground is not recommended.

This specific mode indicator light feature is for the Eaton Push Button only.

The Split Shaft PTO is not available on the UltraShift with a DM3 clutch.

Countershaft PTO

Auto Neutral

AutoShift

Available

Available (Default)

NA

UltraShift AW3

Available

Available (Default)

Available (Default)

UltraShift DM3

NA

Available (Default)

NA

Thru-Shaft PTO

Features

Split Shaft PTO

Note: Refer to Cable section “See Terminals” for correct wire and terminal pin sizes for communication and control wires. See page 39

Front View Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 22

21 36

Pin Side View

73

Features

Power Take-Off “Countershaft driven” PTO input must be a normally open switch. The switch must close to ground whenever the PTO is activated. This input (active when pin 18 is shorted to ground) activates the countershaft PTO mode of the transmission. This feature uses pin 18 of the transmission connector.

Note: The active signal will illuminate the “Mode” indicator only on the Eaton push button console.

The transmission default mode for the pin 18 input is for countershaft PTO operation. Countershaft PTO operation is the default operating mode and no enabling of the countershaft PTO feature is required unless the (pushbutton console) change to “TECU” was previously programmed for split shaft PTO operation.

The input signal wire for the PTO must be isolated from other PTO related circuits.

The ground connection must be isolated from local power device ground returns. Frame rail ground is not recommended.

This specific mode indicator light feature is for the Eaton Push Button only.

Split Shaft PTO

Countershaft PTO

Auto Neutral

AutoShift

Available

Available (Default)

NA

UltraShift AW3

Available

Available (Default)

Available (Default)

UltraShift DM3

NA

Available (Default)

NA

Thru-Shaft PTO

Note: Refer to Cable section “See Terminals” for correct wire and terminal pin sizes for communication and control wires. See page 39

Front View Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

Pin Side View

74

38 22

21 36

Features

Inertia Brake Relocation Instructions 8 to 6-Bolt PTO Opening Removal CAUTION

Oil may be hot.

Note: Drain the lubricant from the transmission. Drain the lubricant from the Inertia Brake. On older product the Inertia Brake will still remain full of lubricant (no drain plug).

1.

Disconnect the Transmission Harness from the Inertia Brake Coil and remove the tie straps restraining this harness branch.

Note: Use care not to damage the harness.

2.

Disconnect the lubricant supply line from the Inertia Brake.The CAUTION

Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake when the mounting bolts are removed.

Remove the six (6) mounting bolts from the Inertia Brake.

4.

Remove the Inertia Brake and gasket from the Adapter Plate.

5.

Remove the eight (8) mounting bolts from the Adapter Plate.

6.

Remove and discard the Adapter Plate and gasket from the transmission.

7.

Remove the six (6) mounting bolts from the 6-bolt PTO cover.

8.

Remove and discard the 6-bolt PTO cover and gasket from the transmission.

Features

3.

Push-in anchor point threaded-hole

Standard Inertia Brake mounting to 8-bolt PTO opening as viewed from the rear of the transmission

Note: Clean and remove all old gasket material from the mating surfacesof the Inertia Brake and transmission PTO openings. Locate the harness push-in anchor point for reference during re-installation to 6-bolt opening.

75

Features

Installation 1.

Clean and thoroughly dry all mating surfaces (including the gasket) prior to assembly.

Note: The transmission Inertia Brake may be mounted to the 6-bolt PTO opening directly, or mounted utilizing a 6-bolt PTO Angle Adaptor to assist in aiding chassis clearance. (See picture below) 2.

If a 6-bolt PTO Angle Adapter is required, install the angle adapter to the 6-bolt PTO opening following the manufacturers instructions. (See picture below)

3.

Inertia Brakes installed without the angle adapter require a new lubrication hose, Eaton part number K3739.

4.

Using the six (6) 3/8 mounting bolts, install the Inertia Brake and gasket, being careful to align the Inertia Brake gear with the drive gear. Tighten mounting bolts to 40-45 lbs. ft. (54-61 N•m) using a cross pattern.

Note: When mounted directly - orient the Inertia Brake housing with hose connection forward and electrical connection rearward, same orientation as 8-bolt. When mounted to a 6-bolt PTO Angle Adaptor - orient the Inertia Brake housing with hose connection rearward / electrical connection forward. Ensure gasket, Inertia Brake and mating mounting faces are assembled dry (no lubricant or grease).

CAUTION

The Inertia Brake is heavy. Be prepared to handle the weight of the Inertia Brake until the mounting bolts are installed.

76

Features

5.

Reconnect the lubricant supply line to the Inertia Brake and tighten to 20-22 lbs. ft. (27-30 N•m).

6.

Relocation kit K-3739 is necessary to perform this next operation.

7.

Connect and route the Transmission Harness to the Inertia Brake Coil. Dress the harness along the transmission case from the Inertia Brake up to the top of the transmission. Install the harness push-in anchor to the threaded-hole anchor point in the Inertia Brake housing. Install tie wraps every 6-10 inches. The harness should not have sharp bends or be under tension. Route harness per letter of instruction. Apply contact lubrication to jumper harness per letter of instruction.

8.

Add UltraShift PTO Instruction Label to dash near PTO switch or a location in view of the driver.

9.

Install the PTO to the 8-bolt PTO opening following the manufacturers instructions.

Note: Fill the transmission with lubricant.

Final Check •

Make sure the mounting bolts are properly tightened.

•

Make sure the lubricant supply line is properly tightened.

•

Make sure the transmission is properly filled with lubricant.

•

Make sure the Transmission Harness is connected and locked.

•

Check for lubricant leaks after operating the vehicle.

•

Check that the Inertia Brake has sufficient clearance to prevent contacting tanks, brackets, frame rails, exhaust or any other part of the vehicle. Contacting anything when stationary or moving will cause damage to Inertia Brake, angle adaptor or other vehicle equipment.

Features

77

Features

Power Take-Off “Thru-Shaft Driven” PTO input must be a normally open switch. The switch must close to ground whenever the PTO is activated. This input (active when pin 18 is shorted to ground) activates the countershaft PTO mode of the transmission. This feature uses pin 18 of the transmission connector.

Note: The active signal will illuminate the “Mode” indicator only on the Eaton push button console.

The transmission default mode for the pin 18 input is for countershaft PTO operation. Countershaft PTO operation is the default operating mode and no enabling of the countershaft PTO feature is required unless the pushbutton console was previously programmed for split shaft PTO operation.

The input signal wire for the PTO must be isolated from other PTO related circuits.

The ground connection must be isolated from local power device ground returns. Frame rail ground is not recommended.

This specific mode indicator light feature is for the Eaton Push Button only.

Split Shaft PTO

Countershaft PTO

Auto Neutral

AutoShift

Available

Available (Default)

NA

UltraShift AW3

Available

Available (Default)

Available (Default)

UltraShift DM3

NA

Available (Default)

NA

Thru-Shaft PTO

Front View Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

Pin Side View

78

38 22

21 36

Features

UltraShift AW3 Auto Neutral Feature All devices mounted on the vehicle that require Auto Neutral function from the Eaton UltraShift AW3 transmission must provide an electrical interface with the transmission. A switch must be used to activate the Neutral mode of the transmission. This feature uses pin 19 of the vehicle connector.

When engaged (switch closed), this feature causes the transmission to neutralize when the vehicle is stopped (i.e. stationary PTO operation) and a transmission gear engagement cannot be selected. When disengaged (switch opened), normal transmission gear engagement can be selected.

The Eaton UltraShift AW3 transmission must have an input signal from the device to activate this feature.

The input signal wire for Auto Neutral must be isolated from other Auto Neutral related circuits.

The ground connection must be isolated from local power device ground returns. Frame rail ground is not recommended.

Split Shaft PTO

Countershaft PTO

Auto Neutral

AutoShift

Available

Available (Default)

NA

UltraShift AW3

Available

Available (Default)

Available (Default)

UltraShift DM3

NA

Available (Default)

NA

Thru-Shaft PTO

Features

Front View Transmission ECU Connector (Vehicle Interface) 37 14

13 35

29

30

31

32

33

34

23

24

25

26

27

28

15

16

17

18

19

20

7

8

9

10

11

12

1

2

3

4

5

6

38 22

21 36

Pin Side View

79

Features

Auto Neutral and PTO Wiring Diagrams The typical relay used for Auto Neutral and PTO wiring is listed below.

•

Bosch: 0332-209-151 (+12 volt), 0332-204-203 (+24 volt) or equivalent

•

HELLA: 4RD 960 388-22 (+12 volt) (Recommended)

•

SIEMENS W28-15F24-S01 (+12 volt)

Note: Use a normally open switch for the PTO “Active” Switch. It can be Mechanical Ball Switch or Air Switch.

Relay Isolated PTO Application Protected Power Battery or VIGN

X

Indicator Lamp

30

85

86

87 87a

Transmission ECU 38-Way Connector (Vehicle Interface)

18 (PTO Switch +) 19 (Auto Neutral AW3 Switch +) Ground

Additional PTO “Active” Switches

PTO “Active" Switches

Battery Negative or Frame Ground

PTO "Active" Switch 1

18 (PTO Switch +) 19 (Auto Neutral AW3 Switch +) Transmission ECU 38-Way Connector (Vehicle Interface) Ground

80

Features

Dual Relay PTO Application (Double Switch) The dual relay option provides one input for transmission PTO operation and another input for the vehicle.

Note: Vehicle can be wired for normally open or normally closed (87 or 87a) Protected Power Battery or VIGN

X 30

85

86

87 87a

Indicator Lamp

30

85

86

87 87a

18 (PTO Switch +) 19 (Auto Neutral AW3 Switch +) Transmission ECU 38-Way Connector (Vehicle Interface)

PTO Switch Input - Vehicle

Ground Additional PTO “Active” Switches

PTO "Active" Switch 1

Battery Negative or Frame Ground

Features

Dual Switch PTO Application

PTO "Active" Switch 1

PTO "Active" Switch 2

18 (PTO Switch +) 19 (Auto Neutral AW3 Switch +) Transmission ECU 38-Way Connector (Vehicle Interface)

PTO Switch Input - Vehicle

Ground

81

Line Inspection

Line Inspection and Road Test Instructions The checklist was developed as an installation tool for line personnel to ensure the correct operation of each vehicle and to assist the vehicle OEM to identify transmission quality related issues as well as OEM line quality issues. Used correctly, this checklist identifies transmission issues and aids in tracking the problem until corrected.

The recommended use of the checklist is as follows: 1.

A separate checklist should be filled out for each vehicle built with Eaton Fuller transmissions. If these checks and information can be combined with an existing form, the Line Inspection form does not need to be used.

2.

The section identified as PRE-START CHECKS should be performed prior to the initial start-up of the vehicle. This section ensures the transmission has the correct power supplies, sufficient lubricant, and correct transmission shift tables.

3.

Perform any necessary corrective action prior to the dyno or road testing.

4.

The DYNO/ROAD TEST section is used to verify that all transmission systems are functional and the Drivers Manual and Shift Label are supplied in the cab.

5.

With a record of transmission related information and repairs made to each unit, the OEM is able to track and correct repeated quality issues.

6.

A copy of the checklist should be recorded for installation history. OEM line personnel should become familiar with the checklist for the transmission prior to a scheduled build. Eaton OEM Engineering Support Group can coordinate training and information to expedite this process.

This checklist represents a generic system which can be tailored to the individual OEM to achieve the best possible method of transmission installation verification. Eaton recommends the use of this system to maintain the utmost in satisfactory operation and long service life.

Each transmission system installed at the OEM must pass the line checklist requirements per the Eaton Line Inspection Form prior to shipment from the OEM plant.

82

Line Inspection

Line Inspection This transmission is equipped with a neutral interlock system that when properly installed prevents the engine from cranking with the transmission in-gear.

WARNING

Failure to perform installation pre-start checks may result in the engine cranking immediately when ignition is moved to the “START” position or to the “ON” position.

To prevent undesired vehicle movement for new installations, always set the parking brake prior to turning the ignition key “ON” and also prior to attempting “START”.

Checklist Instructions/Details for the Line Inspection Forms Refer to the line inspection form while performing the following procedures Note: All information must be filled on the Line Inspection Form.

Pre-Start Checks 1.

Visually verify that the transmission ignition power supply is protected by a manual resetting 10 AMP circuit breaker or fuse and verify that main power is protected by a 30 AMP fuse.

2.

Visually verify that main power is protected by a 30 AMP fuse.

3.

Verify polarity of main power connection.

4.

Verify the transmission has been filled with the correct amount and type of lubricant before starting the engine. Failure to add sufficient lubricant could damage the transmission. See Lubricant Requirement section in this manual for details.

5.

Turn the key switch to the “On” position and visually observe the power up procedure. Gear Display will show a solid “N” when power up is complete.

Note: Make sure Neutral is selected.

WARNING

Improper installation of the OEM Start Enable Circuit could result in enabling the vehicle to be started in gear.

6.

Start the engine and rev it above 1500 rpm. This will allow the DM clutch locking device to disengage and allow normal clutch function (UltraShift DM3 only).

Note: Failure to perform this step will set a clutch disengagement fault and inhibit transmission gear engagement.

Note: UltraShift equipped vehicles with programmable VSS Tamper Resistance options or other artificial engine speed limits which prevent reaching the required 1500 rpm may prevent proper disengagement of the clutch locking device after initial installation. These options may need to be disabled until after the clutch locking device is disengaged.

83

Line Inspection

Note: The transmission will automatically reset to neutral position as soon as the vehicle is powered up (key switch on).

Line Inspection

Dyno/Road Test 1.

With Engine not running, select drive and attempt to start the engine. Repeat for each of the forward and reverse mode positions to verify the engine will not start.

2.

Verify forward and reverse gears can not be obtained without having the service brake applied (UltraShift DM3,AW3 only).

Note: The service brake input is required while selecting a starting gear. If the service brake is not applied while selecting a starting gear, the initial start gear will not be found and the driver will have to re-select neutral and press the brake while reselecting the desired mode.

3.

Verify all forward and reverse gears are obtained.

4.

AutoShift equipped trucks, verify correct clutch adjustment and correct pedal free travel per clutch manufacturer’s specifications.

5.

Verify through normal operations that the transmission temperature gauge (if installed) is functional.

6.

Visually verify that the gear display module is easily visible and lights up when the ignition is turned on.

Note: When testing on a dynamometer which decelerates quickly, the display module may not appear to function correctly.

Should this occur, drive the vehicle off the dynamometer and note how the display functions. If it functions correctly when driving, the problem is that the dynamometer decelerates too quickly.

7.

Verify through normal operation that the engine brake (if equipped) functions correctly per the manufacturer’s specifications.

8.

Verify that the panel lights on the Shift Input Device illuminate when the vehicle dash lights are turned on.

9.

Visually check for lubricant drips or residue on the transmission and related cooler lines (if used).

10. Make sure the correct transmission Shift Label is present and that the Drivers Manual is included with the other vehicle information.

11. Verify the diagnostic connector (6-pin required 9-pin recommended) is easily accessible and mounted on the drivers side of the cab.

12. Verify that a label to alert the customer of type and brand of lubricant used in the transmission is attached to the transmission fill plug.

13. Verify the lube label is affixed near the dipstick tube (UltraShift AW3).

14. Clear historical fault codes by using the key switch. To do this, place the Shift Input Device in neutral and set the parking brakes. Begin with the switch in the on position. Turn the key off and back on six times within five seconds (off/on/off/ on/off/on/off/on/off/on/off/on).

15. Prior to shipment of Eaton Automated Transmission Systems installed at OEM plants, the engine ECU must contain the proper configuration settings. For the proper engine configuration settings required for Eaton Automated Transmission operation refer to the “Engine Configuration Settings Installation Guide” on roadranger.com under the literature center.

84

Line Inspection

Line Inspection Form - UltraShift AW3 Eaton® Fuller® UltraShift AW3

OEM: Chassis S/N:

Line Inspection

Trans Model:

Description

Trans S/N: Yes

No

Corrected

Pre-Start Checks 1.

Ignition Bus Check: Does service light turn on and tone sound?

2.

Power Supply check: (manual reset type) or fuse Min. 10 amp Ignition Bus Min. 30 amp Main Power

3.

Oil Fill (see lubricant section for details)

4.

Power up procedure: System powers up and “N” on Gear Display

DYNO/Road Test Checks Verify the engine doesn't crank in any position other than neutral

2.

Verify all forward and reverse gears obtained with engine control

3.

Verify forward and reverse gear not obtained without service brake applied

4.

Verify transmission temperature gauge is functional - if equipped

5.

Verify gear display module works correctly

6.

Verify engine retarder is functional - if equipped

7.

Verify shift input device panel lights are functional

8.

Verify no transmission oil leaks or residue

9.

Verify the transmission diagnostic connector is accessible

10.

Verify lubricant type and brand label affixed to transmission fill plug

11.

Lubricant type and brand label affixed to the dipstick tube

12.

Verify correct Shift Label

13.

Clear Fault Codes and verify diagnostic connector functions

14.

Prior to shipment of Eaton Automated Transmission Systems installed at OEM plants, the engine ECU must contain the proper configuration settings. For the proper engine configuration settings required for Eaton Automated Transmission operation refer to the “Engine Configuration Settings Installation Guide” on roadranger.com under the literature center.

Line Inspection

1.

Comments:

Signature: Final Inspection Date:

85

Line Inspection

Line Inspection Form - AutoShift AS3

Eaton® Fuller® AutoShift™ AS3

OEM: Chassis S/N:

Line Inspection

Trans Model:

Trans S/N:

Clutch Size/Type: Description Pre-Start Checks 1.

Ignition Bus Check: Does service light turn on and tone sound?

2.

Power Supply check: (manual reset type) or fuse Min. 10 amp Ignition Bus Min. 30 amp Main Power

3.

Oil Fill (see lubricant section for details)

4.

Power up procedure: System powers up and “N” on Gear Display

DYNO/Road Test Checks 1.

Verify the engine doesn't crank in any position other than neutral

2.

Verify correct clutch free travel and adjustment- see OEM clutch literature

3

All forward and reverse gears obtained with engine control

4.

Verify transmission temperature gauge is functional - if equipped

5.

Verify gear display module works correctly

6.

Verify engine retarder is functional - if equipped

7.

Verify shift input device panel lights are functional

8.

Verify no transmission oil leaks or residue

9.

Verify the transmission diagnostic connector is accessible

10.

Verify correct Shift Label

11.

Verify lubricant type and brand label affixed to transmission fill plug

12.

Clear Fault Codes and verify diagnostic connector functions

13.

Prior to shipment of Eaton Automated Transmission Systems installed at OEM plants, the engine ECU must contain the proper configuration settings. For the proper engine configuration settings required for Eaton Automated Transmission operation refer to the “Engine Configuration Settings Installation Guide” on roadranger.com under the literature center.

Comments:

Final Inspection Date: Signature:

86

Yes

No

Corrected

Line Inspection

Line Inspection Form - UltraShift DM3

Eaton® Fuller® UltraShift™ DM3

OEM: Chassis S/N:

Line Inspection

Trans Model:

Description

Trans S/N: Yes

No

Corrected

Pre-Start Checks 1.

Ignition Bus Check: Does service light turn on and tone sound?

2.

Power Supply check: (manual reset type) or fuse Min. 10 amp Ignition Bus Min. 30 amp Main Power

3.

Oil Fill (see lubricant section for details)

4.

Power up procedure: System powers up and “N” on Gear Display

5.

Start engine and rev above 1500 RPM (initial clutch disengagement)

DYNO/Road Test Checks Verify the engine doesn't crank in any position other than neutral and park

2.

Verify forward and reverse gear not obtained without service brake applied

3.

Verify all forward and reverse gears are obtained with engine control

4.

Verify the gear display matches the selected gear

5.

Verify engine ECU contains proper configuration settings for Eaton UltraShift

6.

Verify transmission temperature gauge is functional - if equipped

7.

Verify gear display module works correctly

8.

Verify engine retarder is functional - if equipped

9.

Verify shift input device panel lights are functional

10.

Verify no transmission oil leaks or residue

11.

Verify the transmission diagnostic connector is accessible

12.

Verify correct Shift Label

13.

Verify lubricant type and brand label affixed to transmission fill plug

14.

Clear Fault Codes and verify diagnostic connector functions

15.

Prior to shipment of Eaton Automated Transmission Systems installed at OEM plants, the engine ECU must contain the proper configuration settings. For the proper engine configuration settings required for Eaton Automated Transmission operation refer to the “Engine Configuration Settings Installation Guide” on roadranger.com under the literature center.

Line Inspection

1.

Comments: Final Inspection Date: Signature:

87

Installation Requirements

Line Inspection Form OEM Wiring Connector/Harness Description Deutsch Connector to Transmission ECU 25 +/- 3 lbs. in. [2.82 +/- .33 N•m] Packard Connector to Push Button Controller 10 +/- 3 lbs. in. [1.1 +/.33 N•m] NyoGel 760G lubricant is recommended on connector contacts No lubricant or foreign material on connector jackscrew No contaminants on connector contacts Harness anchor points within 6 in. [15.24 cm] of connectors No unanchored length of harness greater than 12 in [30.48 cm] No sharp bends in the harness Tie wraps on Harness Jacketing only Harness not anchored to objects that are free to move All connectors are fully mated and latches locked All unused connectors or pins should be plugged No exposed splices or wire strands Check DTM04 Connector on Actuator Housing

88

Yes

No

Corrected

Line Inspection

Troubleshooting

Check Transmission Power Circuit

Gear Display shows an “F”?

Yes

Refer to Eaton Troubleshooting Guide for Diagnostic Procedure.

No

Dash “-” on gear Display?

Yes

No

Engine Cranking Problem?

Yes

No

Yes

Verify Start Enable Relay circuit is installed correctly. Verify contacts are connected correctly in the safety neutral circuit. If okay, refer to the Eaton Troubleshooting Guide for Symptom Procedures.

Line Inspection

Transmission Performing Correctly?

Verify transmission is not torque locked; push in the clutch pedal (if installed). Verify Neutral is selected. If dash “-” is still on the gear display, then power down, turn the key off and wait for one minute. Push the clutch pedal in (if installed) and power up.

Resume operation.

No Contact OEM Quality Representative.

89

Appendix

Lifting Eyes and Sensor Positions The Eaton shift bar housing, ECU, sensor, and lifting eye retaining fasteners as well as those associated with any gasketed transmission surfaces are not intended for use in securing additional OEM brackets. Removal of these can compromise transmission system operation and overall system reliability.

No mechanical speedometers. The 10 o’clock position on Heavy Duty and 12’ o’clock position on Medium Duty are reserved for the Eaton speed sensor.

FO-X406X-AW3

Lifting Eyes

Reverse Switch

12 O'Clock Output Shaft Speed Sensor

90

Appendix

F-X40XX-DM3/FO-X40XX-DM3/FO-X40XX-HV

Lifting Eyes

Reverse Switch

12 O’Clock Output Shaft Speed Sensor

Appendix

91

Appendix

RTO-1X910X-AS3/RTO(M)-1X910X-DM3

Do Not Remove these ECU fasteners or attach anything to them

Lifting Eye

Lilfting Eye

Reverse Switch

10 O'clock Output Shaft Speed Sensor

92

Appendix

RTLO-1X918X-AS3/RTLO(M)-1X913X-DM3

Do Not Remove these ECU fasteners or attach anything to them

Lifting Eye

Reverse Switch

Lifting Eye

Appendix

10 O'clock Output Shaft Speed Sensor

93

Appendix

Connector Pin Descriptions Transmission Controller 38-Way (Vehicle Interface Connector) 38-WAY

Description

Wire

38-Way

Description

Wire

1

J1939 Shield (CAN)

16

20

MEIIR Contact

16

2

J1939 Low (CAN)

16

21

MEIIR Minus

16

3

J1939 High (CAN)

16

22

MEIIR Plus

16

4

Start Enable Relay Minus

16

23

Service Light Output

16

5

Not Used

Plug

24

Not Used

Plug

6

Not Used

Plug

25

Shift Control Power Minus

16

7

Not Used

Plug

26

Start Enable Latch

16

8

Not Used

Plug

27

HIL Low (Proprietary CAN)

16

9

Not Used

Plug

28

HIL High (Proprietary CAN)

16

10

J1587 Plus

16

29

Not Used

Plug

11

J1587 Minus

16

30

Not Used

Plug

12

ISO9141-K Communications

16

31

Shift Control Power Plus

16

13

Not Used

Plug

32

Start Enable Relay Plus

16

14

Not Used

Plug

33

Not Used

Plug

15

Shift Control Input 2

16

34

Not Used

Plug

16

Shift Control Input 1

16

35

Ignition

12 GXL or 14SXL

17

Shift Control Input Common

16

36

Battery Minus

12 GXL

18

PTO

16

37

Not Used

Plug

19

Auto Neutral AW3

16

38

Battery Plus

12 GXL

94

Appendix

Cobra Lever 8-way Connector 8-WAY

DESCRIPTION

Wire

1

Shift Control Input 2 (Mode Auto)

16 TXL

2

Shift Control Input (Mode Common)

16 TXL

3

Shift Control Power Minus

16 TXL

4

Shift Control Power Plus

16 TXL

5

Dash Lights

16 TXL

6

Service Light Output

16 TXL

8

Shift Control Input 1 (Mode Manual)

16 TXL

7

No Connection

16 TXL

HV-P Actuator Sensor DTM04

DESCRIPTION

Wire

1

Shift Control Mode Common

16 TXL

2

Shift Control Power Plus

16 TXL

3

Shift Control Input 1

16 TXL

4

Shift Control Input 2

16 TXL

Push Button Shift Control 30-Way Connector 30-WAY

DESCRIPTION

Wire

C1

Shift Control Power Plus

16 TXL

B3

Dimmer Control Input

16 TXL

F1

HIL HIGH (Proprietary CAN)

16 TXL

F2

HIL LO (Proprietary CAN)

16 TXL

J3

Shift Control Power Minus

16 TXL

Appendix

95

Appendix

Transmission Controller 38-Way (Eaton Supplied Assembly) 38-Way

Description

Wire

38-Way

Description

Wire

1

Not Used

Plug

20

Rail Position Sensor Minus

16

2

Clutch Lube Solenoid Plus

16

21

Not Used

Plug

3

Clutch Lube Solenoid Minus

16

22

Not Used

Plug

4

Splitter Solenoid Common Minus

16

23

Output Shaft Speed Sensor High

16

5

Inertia Brake Solenoid Minus

16

24

Output Shaft Speed Sensor Low

16

6

Range Solenoid Common Minus

16

25

Service Ignition

16

7

Input Shaft Speed Sensor High

16

26

Splitter Indirect Solenoid Plus

16

8

Input Shaft Speed Sensor Low

16

27

Not Used

Plug

9

Not Used

Plug

28

Range High Solenoid Plus

16

10

Gear Position Sensor Plus

16

29

Not Used

16

11

Gear Position Sensor Signal

16

30

Not Used

16

12

Gear Position Sensor Minus

16

31

Service Battery Minus

16

13

Clutch Solenoid Plus or Vign ECA

16

32

Splitter Direct Solenoid Plus

16

14

Clutch Solenoid Minus

16

33

Inertia Brake Solenoid Plus

16

15

Main Shaft Speed Sensor High

16

34

Range Low Solenoid Plus

16

16

Main Shaft Speed Sensor Low

16

35

Rail Motor Plus

14SXL

17

Service Battery Plus

16

36

Gear Motor Plus

14SXL

18

Rail Position Sensor Plus

16

37

Rail Motor Minus

14SXL

19

Rail Position Sensor Signal

16

38

Gear Motor Minus

14SXL

96

Appendix

UltraShift DM3 6-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

For Transmission Diagnostics

18 19 20 10 11 12

B

A

C

D

Rail select sensor

A B C

Gear select sensor

A B C

7 8

38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1

Terminating resistor

A B

Input shaft speed sensor 23 24

A B

Output shaft speed sensor B C A

4-way

17 31 25

33 5

A B

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition +

Inertia brake

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

97

Appendix

3 4 1 8 2 3 4 1 8 2

6 5 7 6 5 7

For Transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges Dash lights

10 AMP only manual resetting circuit breaker

25 31 15 16 17 23 35 10 11 26 32 4 22 21 20

or

F

C

A

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

J-1939 Low

B

J

G

10 AMP fuse

H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid 30

Bulkhead connector located at firewall

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

Engine ECM

10 AMP fuse

J-1939/11 data link (OEM supplied)

+

_

GND

98

D

E

J-1939 High

Shield termination

Terminating resistor

Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift DM3 6-Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU Battery power (Non-switched power) run to Battery

OEM

For Transmission Diagnostics

18 19 20 10 11 12

B

A

C

D

Rail select sensor

A B C

Gear select sensor

A B C

7 8

38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1

A

Terminating resistor

B

Input shaft speed sensor 23 24

A B

Output shaft speed sensor B C A

4-way

17 31 25

33 5

A B

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition +

Inertia brake

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

99

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

B3

Dimmer control input

For Transmission Diagnostics per SAE Standard

Back side of gauges Dash lights J-1939 High

10 AMP only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20

or

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

10 AMP fuse

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

10 AMP fuse

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

100

Shield termination

C

A

Terminating resistor

J-1939 Low

B

J

G

30

Bulkhead connector located at firewall

D

E F

H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift HVP 6-Speed Wiring Diagram with Cable Shifter

30 AMP fuse

Transmission ECU Battery power (Non-switched power) run to Battery

38 36

OEM

35 10 11 26 32 4 22 21 20 3 2 1 31 15 16 17

Park sensor

For Transmission Diagnostics

18 19 20 10 11 12

B

A

C

D

1 3 4 2

Rail select sensor

A B C

Gear select sensor

A B C

7 8

A B

Input shaft speed sensor 23 24

Terminating resistor

A B

Output shaft speed sensor B C A

4-way

17 31 25

33 5

A B

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition +

Inertia brake

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

101

Appendix

For transmission diagnostics per SAE Standard J-1939 High

10 AMP only manual resetting circuit breaker 10 AMP fuse

Or 35 10 11 26 32 4 22 21 20

J-1939 Low Ignition Key Switch Runs to main power lead that + Battery feeds the ignition bus (OEM responsible for overcurrent protection on this line) J-1587 data link

Run to starter solenoid Bulkhead connector located at firewall

30

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

10 AMP fuse

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

102

Shield termination

Terminating resistor

D

E F

C

A

B

J

G H

C D B F G A

9-way

Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift AW3 6-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1

Rail select sensor

A B C

Gear select sensor

A B C

7 8

A B

Input shaft speed sensor

For Transmission Diagnostics

23 24

A

Terminating resistor

B

Output shaft speed sensor B

A

C

D 33 5

B C A

4-way B - Service Bat. + C - Service Bat. A - Service Ignition +

A B

Inertia brake

17 31 25

2 3 13 14

Appendix

Hydraulic manifold Assembly Rail select motor 35 37 36 38

Gear select motor

Electric shifter

103

Appendix

3 4 3 4

1 1

8 8

2 2

6 6

Dimmer control input

5 7 5 7

J-1939 High

Back side of gauges Dash lights

Transmission ECU Connector Pins 25 31 15 16 17 23 35 10 11 26 32 4

10 AMP only manual resetting circuit breaker

or

10 AMP fuse

F

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

D

E

J-1939 Low

C

A

+ Battery

B

J

G H

C D B F G A

J-1587 data link

9-way

Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

104

For transmission Diagnostics per SAE Standard

Shield termination

Terminating resistor

Start enable relay

Appendix

UltraShift AW3 6-Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

Bulkhead connector located at firewall

OEM

18 19 20 10 11 12

B C

A

C

D

Gear select sensor

A B C

A B

Input shaft speed sensor 23 24

B

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 27 28 25 31 35 10 11 26 32 4 3 2 1

A

Terminating resistor

B

Output shaft speed sensor

33 5

B C A

4-way B - Service Bat. + C - Service Bat. A - Service Ignition +

A B

17 31 25

Inertia brake

2 3 13 14

Hydraulic manifold Assembly

Appendix

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

105

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

For transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges

B3

J-1939 High

Transmission ECU Connector Pins

10 AMP only manual resetting circuit breaker

27 28 25 31 35 10 11 26 32 4

or 10 AMP fuse

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

C

A

J-1939 Low

B

J

G H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

106

D

E F

Shield termination

Terminating resistor

Start enable relay

Appendix

AutoShift 10-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

C

A

C

D

B

15 16

Input shaft speed sensor

A B

A B

Main shaft speed sensor

Output shaft speed sensor

6 34 28

B C A

Terminating resistor

A

23 24

B

Gear select sensor

B

7 8

For Transmission Diagnostics

Rail select sensor

A

A

38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1

C B A

Range valve

17 31 25

B - Service Bat. + C - Service Bat. A - Service Ignition +

Appendix

4-way Rail select motor 35 37 36 38

Gear select motor

Electric shifter

107

Appendix

3 4 3 4

1 1

8 8

2 2

6 6

Dimmer control input

5 7 5 7

J-1939 High

Back side of gauges Dash lights

Transmission ECU Connector Pins 25 31 15 16 17 23 35 10 11 26 32 4

10 AMP only manual resetting circuit breaker

or

10 AMP fuse

F

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

D

E

J-1939 Low

C

A

+ Battery

B

J

G H

C D B F G A

J-1587 data link

9-way

Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

108

For transmission Diagnostics per SAE Standard

Shield termination

Terminating resistor

Start enable relay

Appendix

AutoShift 10-Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

C

A

A

C

D

15 16

Input shaft speed sensor

A B

A B

Main shaft speed sensor

Output shaft speed sensor

6 34 28

B C A

Terminating resistor

B

23 24

B

Gear select sensor

B

7 8

For Transmission Diagnostics

Rail select sensor

A

A

38 36 27 28 25 31 35 10 11 26 32 4 3 2 1

C B A

Range valve

17 31 25

4-way

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition +

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

109

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

For transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges

B3

J-1939 High

Transmission ECU Connector Pins

10 AMP only manual resetting circuit breaker

27 28 25 31 35 10 11 26 32 4

or 10 AMP fuse

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

C

A

J-1939 Low

B

J

G H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

110

D

E F

Shield termination

Terminating resistor

Start enable relay

Appendix

UltraShift 10-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

A

C

D

Gear select sensor

A B C

A B

15 16

Input shaft speed sensor

A B

23 24

B

A B

Terminating resistor

Main shaft speed sensor

Output shaft speed sensor

6 34 28

B C A

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1

C B A

Range valve

17 31 25

4-way B - Service Bat. + C - Service Bat. A - Service Ignition +

33 5

A B

Inertia brake (Optional)

Appendix

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

111

Appendix

3 4 1 8 2 3 4 1 8 2

6 5 7 6 5 7

For Transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges Dash lights

10 AMP only manual resetting circuit breaker

25 31 15 16 17 23 35 10 11 26 32 4 22 21 20

or

F

C

A

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

10 AMP fuse

J-1939 Low

B

J

G H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid 30

Bulkhead connector located at firewall

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or Engine ECM

10 AMP fuse

J-1939/11 data link (OEM supplied)

+

_

GND

112

D

E

J-1939 High

Shield termination

Terminating resistor

Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift 10-Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

A

C

D

Gear select sensor

A B C

A B

15 16

Input shaft speed sensor

A B

23 24

B

A B

Main shaft speed sensor

Output shaft speed sensor

6 34 28

B C A

4-way

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1

C B A

Terminating resistor

Range valve

17 31 25

33 5

A B

B - Service Bat. + C - Service Bat. A - Service Ignition +

Appendix

Inertia brake (Optional)

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

113

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

B3

Dimmer control input

For Transmission Diagnostics per SAE Standard

Back side of gauges Dash lights J-1939 High

10 AMP only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20

or

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

10 AMP fuse

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

10 AMP fuse

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

114

Shield termination

C

A

Terminating resistor

J-1939 Low

B

J

G

30

Bulkhead connector located at firewall

D

E F

H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift 13-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

Gear select sensor

A B C

A B

15 16

Input shaft speed sensor

A B

23 24

Terminating resistor

A B

Main shaft speed sensor

Output shaft speed sensor B

C

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 25 31 15 16 17 23 35 10 11 26 32 4 22 21 20 3 2 1

A 6 34 28

C B A

D

4 32 26

B C A

4-way

C B A

Range valve

Splitter valve

17 31 25

33 5

Inertia brake

A B

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38

Gear select motor

Electric shifter

115

Appendix

3 4 1 8 2 3 4 1 8 2

6 5 7 6 5 7

For Transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges Dash lights

10 AMP only manual resetting circuit breaker

25 31 15 16 17 23 35 10 11 26 32 4 22 21 20

or

F

C

A

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

10 AMP fuse

J-1939 Low

B

J

G H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid 30

Bulkhead connector located at firewall

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or Engine ECM

10 AMP fuse

J-1939/11 data link (OEM supplied)

+

_

GND

116

D

E

J-1939 High

Shield termination

Terminating resistor

Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

UltraShift 13 Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

Gear select sensor

A B C

A B

15 16

Input shaft speed sensor

A B

23 24

A B

Main shaft speed sensor

Output shaft speed sensor

B

C

6 34 28

A

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 27 28 25 31 35 10 11 26 32 4 22 21 20 3 2 1

C B A

Terminating resistor

Range valve

D

4 32 26

B C A

4-way

C B A

Splitter valve

17 31 25

33 5

A B

B - Service Bat. + C - Service Bat. A - Service Ignition +

Inertia brake (Optional)

Appendix

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

117

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

B3

Dimmer control input

For Transmission Diagnostics per SAE Standard

Back side of gauges Dash lights J-1939 High

10 AMP only manual resetting circuit breaker 27 28 25 31 35 10 11 26 32 4 22 21 20

or

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

10 AMP fuse

Ignition Interrupt relay

86 85 87 87a

* Run to ignition input on Engine ECM

Engine Power Relay Fused 10 AMP manual resetting circuit breaker or

10 AMP fuse

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

118

Shield termination

C

A

Terminating resistor

J-1939 Low

B

J

G

30

Bulkhead connector located at firewall

D

E F

H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid Run to start signal from igntion switch 30 87 86 85

Start enable relay

Appendix

AutoShift 18-Speed Wiring Diagram with Analog Shifter 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

Gear select sensor

A B C

7 8

A B

Input shaft speed sensor

A B

23 24

A

C

D

B

6 34 28

Main shaft speed sensor

C B A

4 32 26

B C A

Terminating resistor

A

Output shaft speed sensor B

Rail select sensor

A

15 16

For Transmission Diagnostics

38 36 25 31 15 16 17 23 35 10 11 26 32 4 3 2 1

C B A

Range valve

Splitter valve

17 31 25

4-way

Appendix

B - Service Bat. + C - Service Bat. A - Service Ignition + Rail select motor 35 37 36 38

Gear select motor

Electric shifter

119

Appendix

3 4 3 4

1 1

8 8

2 2

6 6

Dimmer control input

5 7 5 7

J-1939 High

Back side of gauges Dash lights

Transmission ECU Connector Pins 25 31 15 16 17 23 35 10 11 26 32 4

10 AMP only manual resetting circuit breaker

or

10 AMP fuse

F

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

D

E

J-1939 Low

C

A

+ Battery

B

J

G H

C D B F G A

J-1587 data link

9-way

Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

120

For transmission Diagnostics per SAE Standard

Shield termination

Terminating resistor

Start enable relay

Appendix

AutoShift 18 Speed Wiring Diagram with Push Button 30 AMP fuse

Transmission ECU

Battery power (Non-switched power) run to Battery

OEM

18 19 20 10 11 12

B C

Gear select sensor

A B C

A B

15 16

Input shaft speed sensor

A B

23 24

C

Terminating resistor

A B

Main shaft speed sensor

Output shaft speed sensor B

Rail select sensor

A

7 8

For Transmission Diagnostics

38 36 27 28 25 31 35 10 11 26 32 4 3 2 1

A 6 34 28

D

C B A

4 32 26

B C A

C B A

Range valve

Splitter valve

17 31 25

4-way B - Service Bat. + C - Service Bat. A - Service Ignition +

Appendix

Rail select motor 35 37 36 38

Gear select motor

Electric shifter

121

Appendix

Push Button Shift Control

Push Button Control 30-way connector F2

F1 J3

C1

For transmission Diagnostics per SAE Standard

Dimmer control input Back side of gauges

B3

J-1939 High

Transmission ECU Connector Pins

10 AMP only manual resetting circuit breaker

27 28 25 31 35 10 11 26 32 4

or 10 AMP fuse

Ignition Key Switch Runs to main power lead that feeds the ignition bus (OEM responsible for overcurrent protection on this line)

C

A

J-1939 Low

B

J

G H

+ Battery C D B F G A

J-1587 data link

9-way Run to starter solenoid

Bulkhead connector located at firewall

Run to start signal from igntion switch 30 87 86 85

Engine ECM

J-1939/11 data link (OEM supplied)

+

_

GND

122

D

E F

Shield termination

Terminating resistor

Start enable relay

Appendix

Suggested Tools/Publications Volt/Ohm Meter

(Standard commercially available VOM)

K-Line Special Service Tools 1 (800) 328-6657 K-Line Part no.

Description

RR1009HY

Roadranger Pin Out Adapter Jumper Kit

Circuits Liberty Corporation 1 (269) 226-8743 Part No.

Description

500-432

Pull-To-Neutral Box Gen 3

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

Description MD-200 MD-100

Deutsch 951-765-2250 Part No.

Description

DTT-20-02

Hand crimping tool - Low Power Pins (size 20)

DTT-12-00

Hand crimping tool - High Power Pins (size 12)

Service Publications TRSM-0930

Service Manual for External components

TRTS-0930

Troubleshooting Guide

TRDR-0930

Drivers Instructions for the AutoShift product

TRDR-0940

Drivers Instructions for the UltraShift product

For more information contact your OEM quality representative.

Appendix

123

Appendix

Torque Specifications Description

Torque Value lbs. ft. [N•m]

Transmission-to-Engine capscrews

Refer to OEM for specification

Thread size

Additional Comments

Clutch-to-Flywheel capscrews 7/16 x 2.25 x 14

40 - 50 lbs. ft.

[54 - 68 N•m]

7/16 x 2.25 x 14

3/8 x 2.25 x 16

30 - 35 lbs. ft.

[41 - 47 N•m]

3/8 x 2.25 x 16

M10 x 1-3/8

26 - 35 lbs. ft.

[35 - 47 N•m]

M10 x 1-3/8

M10 x 1-3/4

26 - 35 lbs. ft.

[35 - 47 N•m]

M10 x 1-3/4

6 (Small PTO Cover Capscrews)

20 - 25 lbs. ft.

[27 - 34 N•m]

3/8"-16

Apply Loctite 242 to threads.

8 (Large PTO Cover Capscrews)

50 - 65 lbs. ft.

[68 - 88 N•m]

7/16"-14

Apply Loctite 242 to threads.

4 Electric Shifter Capscrews

30 - 45 lbs. ft.

3/8" - 16 [48 - 61 N•m] cast and 20 - 25 lbs. ft. [27 - 34 N•m] aluminum

Apply Loctite 242 to threads.

1 Reverse switch

20 - 25 lbs. ft.

[27 - 34 N•m]

9/16"-18

1 Neutral switch/cap

20 - 25 lbs. ft.

[27 - 34 N•m]

3/4"-16

3 ECU Capscrews (Medium Duty)

7 - 9 lbs. ft.

1/4" - 20 (9.5 - 12.2 N•m)

3 ECU Nuts (Heavy Duty)

7 - 9 lbs. ft. [9.5 - 12.2 N•m]

.250 - 20 UNC

2 Transmission ECU 38-Way Connectors Capscrews

25 +/- 3 lbs. in.

[2.82 +/- .33 N•m]

M5 x 0.8

3 ECU Bracket Nuts (Heavy Duty)

20 - 25 lbs. ft.

[27 - 34 N•m]

.3125 - 18 UNC

3 ECU Bracket Studs (Heavy Duty)

35 - 45 lbs. ft.

[48 - 61 N•m]

.375 - 16 UNC

2 Harness Bracket Capscrews

20-25 lbs. ft.

[27-34 N•m]

.3125 - 18 UNC

124

Apply Loctite 242 to threads.

Appendix

10 +/- 3 lbs. in.

[1.1 +/- .33 N•m]

2 Push Button Shift Controller Backing Plate nuts and lockwashers

14-16 lbs. in.

[1.58-1.8 N?m]

6 Inertia Brake Capscrews

40-45 lbs. ft.

[54- 61.0 N•m]

3/8"-16

2 LCIB Mounting Studs

60 lbs. ft. [81 N•m]

5/8” - 11

2 LCIB Mounting Nuts

140-150 lbs. ft.

[190-203 N•m]

5/8” - 18

2 Inertia Brake Hose Fittings

30-40 lbs. ft.

[41-54 N•m]

3/4"-16

4 Splitter Solenoid Capscrews

21-27 lbs. in.

[2.4-3.1 N•m]

#10-24

4 Range Solenoid Capscrews

21-27 lbs. in.

[2.4-3.1 N•m]

#10-24

1 Output Shaft Speed Sensor Capscrew (MD)

8-10 lbs. ft.

[10.8-13.6 N•m]

1/4"-20

1 Main Shaft Speed Sensor Capscrew

8-10 lbs. ft.

[10.8-13.6 N•m]

1/4"-20

1 Input Shaft Speed Sensor Capscrew

8-10 lbs. ft.

[10.8-13.6 N•m]

1/4"-20

2 Rail Sensor Capscrews

21-27 lbs. in.

[2.4-3.1 N•m]

2 Gear Sensor Capscrews

21-27 lbs. in.

[2.4-3.1 N•m]

2 Air Filter Regulator Capscrews

8-12 lbs. ft.

[10.8-16.02 Nm]

1/4"-20

1 Lubricant fill plug (6-Speed)

22 - 30 lbs. ft.

[27 - 40 Nm]

3/4-14 NPT

1 Lubricant fill plug (13,10,18-speed)

60 - 75 lbs. ft.

[47 - 61 N•m]

1¼-NPT

2 Lifting Bracket Capscrews

35 - 45 lbs. ft.

[47 - 61 N•m]

3/8"-16

1 Output Yoke Nut (6-Speed)

500 +/- 25 lbs. ft. [678 +/- 34 N•m]

Apply Loctite 242 to threads.

Apply Loctite 242 to threads.

Appendix

1 Push Button Shift Controller 30-Way Connector Capscrew

Apply Loctite 242 to threads.

125

Appendix

1 Output Yoke Nut (13,10,18-Speed)

450 - 500 lbs. ft. [610 - 678 N•m]

4 Rear Bearing Cover Capscrews (6-Speed)

60 - 70 lbs. ft.

[81 - 95 N•m]

1/2-20

Apply Loctite 242 to threads.

4 Rear Bearing Cover Capscrews (13,10,18Speed)

35 - 45 lbs. ft.

[47 - 61 N•m]

3/8-16

Apply Loctite 242 to threads.

Transmission Nodal Mount Capscrews

Refer to OEM for Specification

Transmission Rear Mount Nuts/Capscrews

Refer to OEM for Specification

Apply Loctite 242 to threads.

6 - Speed AW3 Specific Oil cooler line fitting

50 - 60 lbs. ft.

[68 - 81 N•m]

Oil cooler line nut

50 - 60 lbs. ft.

[68 - 81 N•m]

2 Dipstick tube fitting

60 - 70 lbs. ft.

[81 - 95 N•m]

1 WetClutch drain plug

22 - 30 lbs. ft.

[27 - 40 N•m]

12 Flywheel to Drive Coupler Capscrews

3/8 x 16 x 1-1/4 35 - 40 lbs. ft.

[47 - 55 N•m]

High Pressure Oil Filter

25 - 35 lbs. ft.

[34-41 N•m]

1 5/8"-12

Low Pressure Oil Filter HV-P Actuator Housing Bolts

126

Turn until seal touches, then tighten with a 1/2" drive 3/4 to 1 full turn.

30 - 35 lbs. ft.

M8 x 1-1/4

Appendix

Vendor List Eaton Vehicle Controls Business Unit J1939 Auto Shift Display Contact Phone Number: 919 202 5220 http://commercialcontrols.eaton.com

BELDEN WIRE AND CABLE (HIL and J1939 Cable) P.O. Box 1980 Richmond, IN 47375 (317) 983-5200 Fax (765) 983-5294 www.Belden.com

BRAND-REX CO. (J1939 Cable) 300 Brickston Square Andover, MA 01801 (978) 933-5100 www.brand-rex.com

CHAMPLAIN CABLE CO. (J1939 Cable) 12 Hercules Dr. Colchester, VT 05446 (802) 655-2121 Fax (802) 654-4224 www.champcable.com

DEUTSCH Appendix

(Connectors) Industrial Products Division 37140 Industrial Ave. Hemet, CA 92545 (909) 765-2250 Fax (909) 765-2255

127

Appendix

www.deutschipd.com www.laddinc.com (Ladd Industries)

PACKARD Electric (Connectors) Pioneer-Standard Electronics, Inc. Packard Branch 5440 Naiman Parkway Solon, OH 44139 1-800-PARKARD (722-5273) Fax (219) 378-6650 www.delphiconnect.com

RAYCHEM (Wire) Electronics OEM Components Division 300 Construction Drive Menlo Park, CA 94025-1164 1-800-260-9909 Fax United States (800) 260-9999 Fax Worldwide (650) 361-5579 www.raychem.com

ROBERT BOSCH CORPORATION (Relays) 2800 South 25th Avenue Broadview, IL 60153 (708) 865-5301 Fax (708) 865-5203 www.bosch.de

128

Copyright Eaton, 2014.

Eaton hereby grant their customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. It may be copied only in its entirety without any changes or modifications. THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. Note: Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed. Although every attempt has been made to ensure the accuracy of information contained within, Eaton makes no representation about the completeness, correctness or accuracy and assumes no responsibility for any errors or omissions. Features and functionality may vary depending on selected options.

For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger.

In Mexico, call 001-800-826-4357.

Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road.

Eaton Vehicle Group P.O. Box 4013 Kalamazoo, MI 49003 USA 800-826-HELP (4357) www.eaton.com/roadranger Printed in USA