Installation Guide - Roadranger

Fuller® Automated Transmissions

Installation GuideFuller Automated Transmissions

TRIG0050

October 2007

More time on the road ®

RTAO-11710B-AC

RTAO-11710C-AC

RTAO-12710B-AC

RTAO-12710C-AC

RTAO-13710B-AC

RTAO-13710C-AC

RTAO-14710B-AC

RTAO-14710B-AS

RTAO-14710C-AC

RTAO-14710C-AS

RTAO-15710B-AC

RTAO-15710C-AC

RTAO-16710B-AC

RTAO-16710B-AS

RTAO-16710C-AC

RTAO-16710C-AS

RTLO-14918B-AS

RTLO-16918B-AS

RTLO-18918B-AS

RTLO-20918B-AS

1

Table ofContents

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Special Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Shift Lever Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Transmission Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Tower Assembly Space Recommendations . . . . . . . . . . . . . . . . . . . . . . 10

Shift Lever Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System Manager Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 12

Gear Display Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Shift Lever Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gear Display Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Gear Display Module

Electrical System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21AutoSelect™ and AutoShift™ SystemTypical Vehicle Interface HarnessGear Display HarnessTypical Start Enable CircuitATA (J1587) Diagnostic HarnessDimmer Control Input ConnectionIgnition Circuit Breaker Power HarnessTypical Engine Brake Inhibit CircuitTypical Transmission Interface Harness - AutoShiftTypical Transmission Interface Harness - AutoSelectMain Logic GroundMain Logic Power (+12 Volts)Power ConnectionsSAE J1939 Recommended Cable Termination ProcedureJ1939 "Backbone" Communication HarnessJ1939 "Backbone" Interface HarnessLocation of the J-1939 Control Data Link on All Caterpillar Electronic EnginesLocation of the J-1939 Control Data Link on Detroit Diesel DDECIII EnginesLocation of the J-1939 Control Data Link on Cummins Engines

2

Table ofContents

Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Checklist InstructionsDyno/Road TestLine Inspection Form

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Oil Cooler Chart

Appendix I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48System Overview (Typical Truck Application)

Appendix II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Tower Assembly ConnectorsShift Lever ConnectorsSystem Manager ECU ConnectorsTransmission Interface Harness (AutoShift™) ConnectorsTransmission Interface Harness (AutoSelect™) ConnectorsVehicle Interface Harness ConnectorsGear Display ConnectorATA ConnectorTransmission Sensor Position - TopTransmission Sensor Position - LeftTransmission Controller ConnectorsCaterpillar J1939 ConnectorDetroit Diesel J1939 Connector

Appendix III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Torque Specifications

Appendix IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Vendor List

Appendix V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Quick Reference

Harness SchematicsAutoShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63AutoSelect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

3

Foreword

This Eaton publication is intended to be a reference guide for the installation of allAutoSelect™ and AutoShift™ series transmissions. As much general vehicle andtransmission information has been given for covering the wide range of applications.This information benefits the OEM installer by providing the correct installation proce-dures to ensure the utmost in satisfactory operation and long service life. For additionaltransmission information, see “Related Publications” of this booklet. For specific engineinformation contact engine OEM.

Specific Truck OEM Installation Requirements are shown shaded in each section.

Failure to adhere to Eaton Installation Requirements may effect transmission perfor-mance and/or warranty coverage.

AutoSelect transmissions are compatible with mechanically or electronic governedengines. AutoShift transmissions are compatible with electronically governed enginesequipped with a J-1939 data link and certified by Eaton Corporation. These transmis-sions installed at OEM facilities must meet and be approved by the application require-ments outlined in Form FUL-219.

All information contained in this manual was accurate at the time of printing. With eachnew application, engine manufacturers should be contacted to make sure desiredengines are compatible with the AutoSelect or AutoShift systems.

4

SpecialTool

RequirementsSuggested Tools

OTC Tool & Equipment Division, SPX CorporationDescription

Volt Ohm Meter(Standard commercially available VOM)

Micro Processor Systems, Inc. (MPSI )Part No. Description

104004 Pro-Link Main (MPSI Hand-held diagnostic tool)205020 Heavy Duty Multi-Protocol Cartridge (MPC)805001 MPC Eaton Systems Software206024 Caterpillar Software Cartridge version 1.06204038 J1939/EPL Link Tester

MPSI Phone Orders 1-800-639-6774

Kent-Moore Inc.Part No. Description

J-38500-750 DDC DDEC II & DDEC III Software Cartridge

Kent Moore Phone Orders 1-800-328-6657

5

RelatedPublications

Troubleshooting GuideAutoSelect™ Eaton TRTS-0050AutoShift™ Eaton TRTS-0050

Driver InstructionsAutoSelect Eaton TRDR-0040AutoShift Eaton TRDR-0060

Service ManualAutoSelect Eaton TRSM-0050AutoShift Eaton TRSM-0050

Illustrated Parts ListAutoSelect Eaton TRIP-0041 (12710)AutoSelect Eaton TRIP-0043 (14710)AutoSelect Eaton TRIP-0045 (16710)AutoShift Eaton TRIP-0064 (14710)

Small Scale Print #’s

AutoSelect

RTAO-10710B/C-AC 114-ADRTAO-12710B/C-AC 114-ADRTAO-14710B/C-AC 092-ADRTAO-16710B/C-AC 092-AD

AutoShift

RTAO-10710B/C-AS 121-ADRTAO-12710B/C-AS 121-ADRTAO-14710B/C-AS 115-ADRTAO-16710B/C-AS 115-ADRTLO-14918B-AS 165-ADRTLO-16918B-AS 165-ADRTLO-18918B-AS 165-ADRTLO-20918B-AS 165-AD

Lubrication RequirementsTCMT-0019

For more information, phone 1-800-TCM-HELP (826-4357)

6

All AutoSelect™ and AutoShift™ transmission systems installed at OEM facilities mustmeet the requirements and be approved using Eaton Automated Transmission Applica-tion Approval Form FUL-219. The form can be viewed in the "Application Information"section.

1. Air Dryer Requirements - A high quality commercially available vehicle air dryer isrequired to be used in conjunction with both AutoSelect and AutoShift transmissionsystems.

2. Clutch Requirements - Spring dampened clutches are required for all applications.

3. Electrical Wiring Requirements -

All wires except EPL and J1939 are to be a minimum of 16 gauge GXL.

EPL (the communications link between the System Manager and the Transmis-sion Controller ECUs) must be a twisted shielded pair: Belden, J1939, orequivalent.

J1939 (the communications link between the System Manager ECU and theEngine Controller ECM) must be shielded pair as specified by SAE J1939.

SAE J-1587 connector must be easily accessible and mounted on the left sideof the cab.

4. Harnesses - At no time should any AutoSelect or AutoShift harness be spliced tosupply another system with information. Usage of cabling for any purpose otherthan transmission control could cause a system failure.

5. Line Inspection - All Eaton transmission systems installed at OEM Plants must passthe requirements outlined on the checklist form included in "Line Inspection"section prior to shipment.

6. Lubrication Requirements - Transmission Oil - Eaton Roadranger CD50 or equiva-lent synthetic as specified in Eaton publication TCMT-0019.

7. Power

Battery (+) and (-) must be disconnected PRIOR to any type of welding on anyAutoSelect or AutoShift equipped vehicles.

8. Spatial Requirements - The AutoSelect and AutoShift transmission systems requirea minimum of 4" clearance from any high temperature devices (i.e. ExhaustCrossover Pipes). These systems to be avoided are the Shift Motors, Range Valve,and Transmission ECU.

9. Speedo’s - No mechanical speedo’s.

10. Eaton approved oil to water oil cooler required for 18 speed transmissions.

11. A cab floor access plate is necessary so that service personel can access andremove components from the transmission top, if necessary. Plate size must besufficient to allow removal of the transmission controller or the XY shifter.

GeneralInstallation

Requirements

7

Tower Mounted Shift Lever1. Eaton supplied tower assembly is required.

2. Sealed bulkhead style harness connectors must be used when running harnessconnections through cab floor or firewall.

3. The tower assembly must be situated in the cab within easy reach and sight of thedriver’s normal position. (See Shift Lever Mounting information section)

4. The System Manager’s housing must be connected to chassis ground. If the towerassembly is mounted on a conductive surface, the connection is complete and nofurther action need be taken. If the tower assembly is mounted on a non-conduc-tive surface, the chassis ground connector (located on the tower assembly harness)must be connected to one of the mounting bolts of the System Manager. If theground connection is needed and the ground connector is not present, contact theEaton Customer Quality Group at (616) 342-3000.

5. If the tower mounted shift lever is used, it the OEM's responsibility to ensure thetower assembly is rigidly mounted. As a guideline, a minimum floor thickness inthe mounting area of 0.250" for alumimum (0.125" for steel) is recommended.

Shift LeverRecommenda-tions

8

TransmissionSpace

Requirements

1000-11-97

1001-11-97

110 [4.36]

26.6[1.05]

88.1[3.47]

119.4[4.70]

734.6 [29.46]

205.7[8.10]

186.5[7.34]

283.0[11.14]

283.0[11.14]

287.3[11.3]

63.5[2.50]

63.5[2.50]

212.6[8.37]

264.3[10.41]

182.1[7.17]

10 Speed

9

TransmissionSpaceRequirements

18 Speed

1037-8-98

212.6[8.37]

287.3[11.3]

63.5[2.50]

63.5[2.50]

283[11.14]

128.27[5.050]

269.49[10.610]

303.53[11.950]

118.43[4.663]

182.1[7.17]

264.3[10.41]

283.0[11.14]

93.6[3.69]

186.5[7.34]

205.7[8.10]

840.8[33.10]

225.6[8.88]202.0[7.95]

45.1[1.77]26.6[1.05]

110.7[4.36]

90.5[3.56]

63.29[2.492]

235.96[9.290]

10

TowerAssembly

Recommenda-tions

Typical Tower Mount Configuration

1004-3-97

SW

LOGI

C

SYSM

AN

COM

MSY

SMAN

SERV

ICE

VEHI

CLE

RELA

Y

TRAN

SMIS

SION

DCC

DASH

Reinforcedcab floor witheasily accessableand removable transmission access plateAluminum = 0.250" ThickSteel = 0.125" Thick

11"

23"

Sealing bulkhead style connectorsthrough cab floor

Note: The desired installation position is wherethe shift lever handle "FALLS TO HAND" when the lever is in the "H" - Hold Position, for driverselected shifts.

DASH

DriversSeat

PassSeat

17"

L

RVOLUME

5.240"

5.592"

6.500"

9.500"

11

Shift Lever

46.36[1.825]

[4.800]

[2.625]66.67

[6.620]

LR

D HOLD LHR N

127.00

84.07[3.310]

84.07[3.310]

A B C

A B C

[4.375]

121.92

[5.000]

111.12

232.41 [9.150]

Dimensions shownare: mm [in]

10.92 [.430]63.50[2.500] .540

168.15

VOLU

ME

4 X - 20 UNC14 —

1020-11-97

Shift LeverSpaceRequirements

12

System Manager ECU

7.373X Ø THRU

209.55


43.05

[6.505]165.23

68.28 [2.688]

136.52 [5.375]

[7.500]190.50

[.290]

[1.695]

[8.250]

9.53 [.375]

177.55 [6.990]

SystemManager

SpaceRequirements

1021-10/93

13

Gear Display Module

1014-1-97

Part No. 4302640

GearDisplaySpaceRequirements

TruckComponents

33.93 [1.336]

[2.190]

[2.350]

[1.850]46.99

55.63

40.89

4.0 [.16]

42.93 [1.690]

2.0 [.08]2.0 [.08]

[1.610]

59.69


Panel cut-out :43.1 [1.70] X 56.1 [2.20] – 0.254 [.010]

14

TransmissionMounting10 Speed Handling

1. Handle the transmission carefully to avoid damage to the transmission componentsand to surrounding vehicle components.

2. Use a hoist or transmission jack that permits precise control of transmissionmovement during installation.

Transmission Preparations (10 Speed)

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

2. If a thread-in electronic speedometer system is used, Eaton P/N 4301954 (seal) isused to seal the threads. Tighten sensor or sensor lock nut to 35 Lbf·ft, (3/4-16threads).

If a push-in sensor is used, Eaton P/N 14142 (O-ring) and Eaton P/N 71206(silicone lubricant) are used to seal the sensor.

3. If necessary to remove, reposition, or replace rear bearing cover, always replacenylon sealing collar (Eaton P/N 19709) and brass washer (Eaton P/N 20807) on thecapscrew located at the chamfered hole in the rear bearing cover. Apply EatonSealant P/N 71205 or equivalent to threads and tighten mainshaft rear bearingcover capscrews to 35-45 Lbf·ft (3/8-16).

4. To install replacement mainshaft output seal (Eaton P/N 20807) and slinger (EatonP/N 20808) use Eaton installation tool (K-2091).

Output Yoke/Flange Installation (10 Speed)

Note: The output yoke/flange will be supplied with the transmission. However,if the output yoke/flange must be replaced, the following procedure should befollowed.

1. Select the proper output yoke/flange per specified application, remove plasticcover, and inspect the slinger (gold anodized ring) and seal surface for damage orcontamination. Do not use the yoke/flange if the slinger or seal surface is damaged(dents, nicks, scratches, etc.).

2. All contamination (Styrofoam particles dust, dirt, rust, etc.) on the machined sealsurface of the yoke/flange must be wiped off or removed prior to installation.

3. Place the yoke/flange over the transmission output shaft end and rotate it to line upthe splines. Take care not to bump any machined surface of the yoke/flangeagainst the output shaft. Push the yoke/flange all the way onto the output shaft andonto the seal with one continuous motion.

4. Thread the tailshaft nut onto the tailshaft until nylon insert is engaged on thetailshaft thread. Secure yoke/flange and tighten the tailshaft nut to 450-500 Lbf·ft.

15

Handling

1. Handle the transmission carefully to avoid damage to the transmission componentsand to surrounding vehicle components.

2. Use a hoist or transmission jack that permits precise control of transmissionmovement during installation.

Transmission Preparations (18 Speed)

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

2. A push-in electronic speedometer system sensor is used, Eaton P/N 14142 (O-ring)and Eaton P/N 71206 (silicone lubricant) are used to seal the sensor.

3. If necessary to remove, reposition, or replace the rear bearing cover, always applyEaton Sealant P/N 71205 or equivalent to threads and tighten mainshaft rearbearing cover capscrews to 35-45 Lbf·ft (3/8-16).

4. To install replacement mainshaft output seal (Eaton P/N 4302322) and slinger(Eaton P/N 4302323) use Eaton installation tool kit (TCMT-0912).

Output Yoke/Flange Installation (18 Speed)

Note: The output yoke/flange will be supplied with the transmission. However,if the output yoke/flange must be replaced, the following procedure should befollowed.

1. Select the proper output yoke/flange per specified application.

2. Place the yoke/flange over the transmission output shaft end and rotate it to line upthe splines. Push the yoke/flange all the way onto the output shaft and onto theseal with one continuous motion.

3. Thread the tailshaft nut onto the tailshaft until nylon insert is engaged on thetailshaft thread. Secure yoke/flange and tighten the tailshaft nut to 450-500 Lbf·ft.

TransmissionMounting18 Speed

16

TransmissionMounting

Mounting To Engine

1. Use the two transmission lifting eyes provided.

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

3. Inspect the engine to transmission mating surfaces for damage or debris prior to installa-tion. Engine flywheel housing face, transmission clutch housing face, input shaft, etc.should be free of paint, debris, rust, and any type of damage before installation.

4. INPUT SHAFT TO CLUTCH ALIGNMENT: The transmission will be delivered from Eatonwith the main box and auxiliary section in gear. The transmission must be in gear (bothwith the main box and auxiliary) 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 ispowered 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 will be in gear until thevehicle is power up with the key switch, the transmission prop shaft must be installedwhile the axles can be rotated to allow for alignment.

5. Adjust the lift chain to 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 housingmust be parallel during installation. If the transmission is properly aligned and the clutchis installed properly, very little force is required to slide the input shaft through the clutchand into the pilot bearing.

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

7. Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up splines.Position the clutch release mechanism into proper position according to style used.

NOTE: The clutch release lever will require removal during installation if interference isencountered with the transmission ECU. See figures on this page.

8. Once the transmission is seated against the engine flywheel housing, align the clutchhousing bolt holes with the engine flywheel bolt holes and install all cap screws to fingertight.

NOTE: The clutch housing must be flush against the engine fly wheel housing beforetightening any capscrews. Do not use the capscrews to seat housing.

9. Tighten four mounting screws at 90° intervals around the clutch housing, then tighten theremaining transmission mounting capscrews using the recommended torque specifica-tions.

NOTE: Do not tighten any mounting capscrew until all capscrews have been installedand finger tightened. Do not remove the transmission support chain or jack until allmounting bolts have been tightened.

10. Inspect the clutch release mechanism for proper and free operation. If binding or non-operational, repeat steps 6 through 9.

Clutch Release Lever

1003-10/93

1002-10/93

17

LubricationRequirements

Eaton® Fuller® transmissions are designed so that the internal parts operate in a bath ofoil circulated by the motion of gears and shafts. Thus, all parts will be amply lubricatedif these procedures are closely followed:

1. Use Eaton® Roadranger® CD50 or equivalent synthetic per Eaton publicationTCMT-0019.

2. When adding oil, types and brands of oil should not be mixed because of possibleincompatibility.

3. Use clean oil and clean containers when filling the transmission. Containers thathave been used for antifreeze or water should not be used for transmission oil.

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

transmissions.

NOTE: Failure to adhere to Eaton Installation Requirements may effect AutoSelect™/AutoShift™ performance and/or warranty coverage.

Proper Oil Level

Oil Capacity 10 Speed 26 pints (12.3 liters)18 Speed 27 pints (13 liters)

NOTE: Actual quantity for proper fill level will vary from unit to unit.

Make sure oil is level with fill hole opening. Because you can reach oil with your fingerdoes not mean oil is at the proper level. One inch of oil level is about one gallon of oil.

Proper Oil LevelImproper Oil Level

Grade(SAE)

Recommended Lubricant

Eaton® Roadranger®

CD50 TransmissionFluid

Type

Fahrenheit (Celsius)Ambient

Temperature

50 All

Includes all Eaton Approved comparable synthetic oils

18

Tower Mounted Shift Lever1. Minimum floor or support plate thickness for mounting the tower assembly is .250"

for aluminum or .125" for steel. The OEM is responsible for providing a towermounting surface sufficient to make the shift tower “feel solid”.

2. The provided bulkhead connectors must be mounted such that they preventcontamination from entering the tower area.

3. The shift tower assembly must be mounted in the cab within easy reach of thedriver’s normal position. NOTE: The desired position would be where the lever “fallsto hand “ in the H-hold position.

4. The shift tower assembly should not interfere with other vehicle related controls orfeatures located in the surrounding vicinity.

5. A service port connector is located inside the tower assembly, so the tower shouldbe mounted to provide easy removal of the inspection cover.

6. If the tower is mounted to other than a metal surface, the tower must be groundedto chassis.

7. If the shift tower is not mounted on a removable plate, an access floor plate isnecessary to service components on the transmission top.

Console, Direct, or Other than Eaton Tower Mounted ShiftControls1. The shift lever and System Manager must be mounted to prevent contamination

from entering where they are mounted.

2. The System Manager, power connect relay and service port can be mounted in aremote location to the shift lever .

3. The OEM is responsible for providing a wire harness to connect the SystemManager to the shift lever, power connect relay, service port, and transmission. Awire diagram can be found in the back of this guide. All wires must be 16 AWGGXL or equivalent. The Eaton Proprietary Link (EPL) must be a twisted shieldedpair—Belden P/N 85231 or equivalent. Pins H and J are not shown as populated inthe wiring diagram; however, they need to populated for Eaton engineering pur-poses. Service port Pin H is connected to the 32-way connector Pin D2 on thesystem manager. Service port Pin J is connected to the 32-way connector Pin C16on the System Manager.

4. The System Manager can be mounted in any configuration, except connectors up.This will prevent fluid from pooling inside the connector and ECU.

5. The System Manager enclosure MUST BE CONNECTED TO CHASSIS GROUND.

6. The power connect relay must be Bosch part number 0332204171 or equivalent.

7. The AutoSelect™ service port is for trouble shooting the transmission only (it is notJ-1587 compatible). The service port should be placed out of sight near the shiftlever if possible.

8. The shift lever must be mounted on a surface with sufficient stiffness to provide a “firm feel”.

9. Any bulkhead connectors used must be sealed to prevent contamination.

10. The throw of the shift lever should be taken into account to prevent interferencewith other components near the lever.

Shift LeverMounting

19

20

Gear Display Module

TruckComponents

Dimensions shown are: mm [in]

Panel cut-out:43.1 [1.70 X 56.1 [2.20]

Mounting Panel Thickness:2.70-3.30 [.160-.129]

Eaton P/N 4302640

1014a-10/93

GearDisplay

Mounting

21

ElectricalSystemRequirements

AutoSelectTM and AutoShiftTM SystemThe dash area is the location for the following:

Start Enable Relay

Gear Display Module

ATA Connector (1587 Link)

Dimmer Control Input (Vdash)

Ignition Power (Vign)

Engine Brake Inhibit Relay (Mechanical Governed Engines Only)

1023-3-97

0

500

1000

1500

2000

2500

TACHRPM 0

10

20

30

4050 60

70

80

90100

TACHRPM

CABE

A B

CDE

F

SW

LOGI

C

SYSM

AN

COM

MSY

SMAN

SERV

ICE

VEHI

CLE

RELA

Y

TRAN

SMIS

SION

DCC

Dimmer Control Input

Start Enable Relay

Engine Brake Inhibit Relay(Mechanically Governed Engines Only)Firewall

Floor Board

ATA Connector(J1587 Link)

TransmissionInterfaceHarness

J1939 Engine Link(AutoShift Only)

Vehicle Interface Harness

Note: J1939 InterfaceRequires the "BACKBONE"(See J1939 Backbone Diagram for details)

J3

J2

EPLLink

TerminatingResistor

TerminatingResistor

J1939 Data Link(OEM supplied)

EngineECM

Engine

Power Leadsto Starter

C.B. or Fuse

IgnitionBus

22

ElectricalSystem

RequirementsTypical Vehicle Interface Harness

Z

Z

VIEW Z - Z

A

B

C

D

E

F

G

HJ

K

L

M

NP

Twisted Pairs

ATA (-)ATA (+)

ATA (+)ATA (-)

Wires to be twised pair with a minimum of (1) twist per 25.4mm [1.00 in] per SAE-1708

All Wires are 16 Gauge GXL per J-1128Interconnection Table

J1-AJ1-BJ1-CJ1-DJ1-EJ1-FJ1-GJ1-HJ1-JJ1-KJ1-LJ1-MJ1-NJ1-P

J2-AJ2-BJ2-CJ2-DJ2-EJ2-FJ2-GJ2-HJ2-JJ2-KJ2-LJ2-MJ2-NJ2-P

FROM TO WIRE DESCRIPTIONCLOCK (+)DATA (-)GEAR DISPLAY POWER (+)GEAR DISPLAY POWER (-)ATA (+)ATA (-)E-BRAKE (+)SPARE 1START_EN (+)SPARE 2VIGNVDASHGROUNDSPARE 3

J1 J2

1006-1-97

Required For ShiftTower Mount

Typical InterfaceAt Firewall

23


1014a-1-97

Gear Display Harness

TruckComponents

Dimensions shown are: mm [in]

Panel cut-out :43.1 [1.70] X 56.1 [2.20]

Mounting Panel Thickness:2.70-3.30 [.160-.129]

J334321

ECU CONNECTOR WIRE TABLEDRIVER COMMAND CONSOLE (24 PIN)WIRE DESCRIPTION PIN LOCATIONClock (+) B11Data (-) B10Display Power (+) A3Display Power (-) B2

EATON P/N4302640

FIREWALL/GEAR DISPLAY CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONClock (+) AData (-) BDisplay Power (+) CDisplay Power (-) D

PIN LOCATIONFirewall Gear Display (J33)

3214

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

Shift Lever 24-Way Connector

A

B

C

D

E

F

G

HJ

K

L

M

NP

Top View

Pin 4 Pin 1

Top View

24

ElectricalSystem

RequirementsTypical Start Enable Circuit

Startability must meet FMVSS Standard 102, Section 3.1.3: "The engine starter shall beinoperative when the transmission shift lever is in a forward or reverse direction position."

1012-1-97

ECU CONNECTOR WIRE TABLESystem Manager 24-Way ConnectorWIRE DESCRIPTION PIN LOCATIONSTART_EN (+) A1

FIREWALL CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONSTART_EN (+) J

Firewall

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

System Manager 24-Way Connector

A

B

C

D

E

F

G

HJ

K

L

M

NP

Use Bosch:Relay : 0332-024-151 (+12 Volt) or equivalent

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

START_EN (+) Run to Start Post of Ignition Switch

Run to Starter Solenoid

85 30

86 87a 87START_EN (+)

1N4007

Run to StarterSolenoid

Run to Start Post of Ignition Switch

+BATT

KEYSWITCH

ACC

OFF

IGNITION

START

Relay Coil

Relay N.O.

START_EN (+)

D1

In Cab

STARTERSOLENOID

Note: D1 is used to latch the relay duringstart-up

D1 = 1N4007

Relay Schematic

25


ATA (J1587) Diagnostic Harness

ECU CONNECTOR WIRE TABLESystem Manager 32-Way ConnectorWIRE DESCRIPTION PIN LOCATIONATA (+)

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12


FIREWALL/ATA CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONATA (+) EATA (-) F

PIN LOCATIONFirewall ATA Connector

AB

A

B

C

D

E

F

G

HJ

K

L

M

NP

ATA (-)C1D14

D13 D14 D15 D16

C13 C14 C15 C16

CABE

+VBATT

ATA CONNECTOR WIRE TABLEWIRE DESCRIPTION PIN LOCATIONATA (+)

ATA (-)

A

B

ATA (+)

ATA (-)

+VBATT

Ground

C

E

A B

CDE

F

NOTE: The Diagnostic Connector must be mounted on the left side of the cab and easily accessible per SAE J-1587.

26

ElectricalSystem

RequirementsDimmer Control Input Connection

1016-1-97

ECU CONNECTOR WIRE TABLESHIFT LEVER (24 PIN)WIRE DESCRIPTION PIN LOCATIONVDASH A10


WIRE DESCRIPTION PIN LOCATIONVDASH M

Firewall

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


A

B

C

D

E

F

G

HJ

K

L

M

NP

To Shift Lever

VDASH

Back of Dash

Gauges

Dash Lights

Connect VDASH to the dash lights or running lights.This input will dim the lights on the Driver Command Consoleand the Gear Display Module. When VDASH input is off,the lights on the Shift Lever and the Gear Display Module will be on full.

27


Ignition Circuit Breaker Power Harness

1017-3-97

ECU CONNECTOR WIRE TABLESHIFT LEVER (24 PIN)WIRE DESCRIPTION PIN LOCATIONVIGN A1


WIRE DESCRIPTION PIN LOCATIONVIGN L

Firewall

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


A

B

C

D

E

F

G

HJ

K

L

M

NP

ECU CONNECTOR WIRE TABLESystem Manager 24-Way ConnectorWIRE DESCRIPTION PIN LOCATIONVIGN A10

AUX +BATT(Preferred Protection)10 Amp AutomaticResetting Circuit BreakerLocate in Fuse Panel(Acceptable Protection)10 Amp Fuse

NOTE: The Circuit Breaker Must Be Labeled. (i.e. TRANSMISSION POWER)

Ignition Power(Switched Power)Run to Main Power leadthat feeds the Ignition Bus

To System Manager ECUand Shift Lever

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


28

AutoSelect™ OnlyElectrical

SystemRequirements

Typical Engine Brake Inhibit Circuit

1011-4-97

ECU CONNECTOR WIRE TABLESystem Manager 24-Way ConnectorWIRE DESCRIPTION PIN LOCATIONE-BRAKE (+) A3


WIRE DESCRIPTION PIN LOCATIONE-BRAKE (+) G

Firewall

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


A

B

C

D

E

F

G

HJ

K

L

M

NP

Use Bosch:Relay : 0332-024-151 (+12 Volt) or equivalent

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

E-Brake (+) Run to Ignition Circuit Breaker

Run to Engine Brake Power Switch

85 30

86 87a 87

E-BRAKE (+)Run to Engine Brake Power Switch

Run to IgnitionCircuit Breaker

+Ignition

Relay Coil

Relay N.C.

Relay Schematic

To EngineBrake Circuit

E-Brake (+)

An Engine Brake Inhibit Relay for AutoSelect™ Mechanically Governed Engines must be installedeven if the vehicle is not equipped with an engine brake. If engine is not equipped with an engine brake, insulate unused relay contacts.

NOTE: Typical engine brake installationis with the relay contacts between the circuit breaker and the Engine Brake Power Switch

Engine BreakPower Switch

Mechanically Governed Engines Only

29


Typical Transmission Interface Harness

AutoShift™

J2 J1

Z

Z

VIEW Z - Z

A

B

C

D

E

F

G

HJ

K

L

M

NP

The following harnesses will have to be supplied by the OEM: Transmission Interface Harness, Vehicle Interface Harness, Dash Harness, and J-1939 Backbone.

J1 CONNECTOR WIRE TABLE

AutoSelect Transmission Interface HarnessWIRE DESCRIPTION TO PIN LOCATION

EPL-HIGH J3-A

FROM PIN LOCATION

J1-A

EPL-LOW J3-BJ1-B

EPL-SHIELD J3-CJ1-C

+VBATT

TRANS_GND

BATT 1

J2-D

J1-F

J1939 (+)

J2-E

J1-G

J1-E

J1-H

J1-D

J2-F

J4-A

J4-B

J4-C

J2-C

J1939 (-)

J1939 SHIELD

+VBATT 2

TRANS_GND

BATT 2

NONE

J1-J

J1-K

J1-L

J1-M

J1-N

J1-PNONE

J2-B

J2-A

PLUG

PLUG

(FROM POWER CONNECT RELAY OUTPUT)


TWISTED PAIRSEPL-HIGH

EPL-LOW

EPL-LOW

EPL-HIGHEPL-SHIELD EPL-SHIELD

Wires are to be twisted pair.With a minimum of one (1)twist per 25.4mm [1.00 in] perSAE-J1708. Wires must be wrapped using drain wire with foil shield for the full length ofthe wires. Drain wire is not to be exposed to environment. Splice crosslink approximately 76.2mm [3.00 in] from endto noninsulated drain wire. See J1939 Section.For EPL use Belden Cable P/N 85231 or equivalent. For J1939 use SAE approved twisted shielded pair wire. SeeJ1939 BACKBONE information for approved manufactuers

All wires are to be 16 AWG GXL per SAE J-1128

TWISTED PAIRSJ1939-HIGH

J1939-LOW

J1939-LOW

J1939-HIGHJ1939-SHIELD J1939-SHIELD

J1939 Connector

J4

EPL Connector

Note: See J1939 BACKBONE section for connector and length information

J3

1005a-11-97

Note: Can also be used for AutoSe-lect (J4 should be sealed with anappropriate cap if unused.)

30

ElectricalSystem

Requirements

AutoSelect ™Only

The following harnesses will have to be supplied by the OEM: Transmission Interface Harness, Vehicle Interface Harness, and the Dash Harness.

J1 CONNECTOR WIRE TABLE

AutoSelect™ Transmission Interface HarnessWIRE DESCRIPTION TO PIN LOCATION

EPL-HIGH J3-A

FROM PIN LOCATION

J1-A

EPL-LOW J3-BJ1-B

EPL-SHIELD J3-CJ1-C

+VBATT

TRANS_GND

BATT 1

J2-D

J1-F

NONE

J2-E

J1-G

J1-E

J1-H

J1-D

J2-F

PLUG

PLUG

PLUG

J2-C

NONE

NONE

+VBATT 2

TRANS_GND

BATT 2

NONE

J1-J

J1-K

J1-L

J1-M

J1-N

J1-PNONE

J2-B

J2A

PLUG

PLUG



TWISTED PAIRSEPL-HIGH

EPL-LOW

EPL-LOW

EPL-HIGHEPL-SHIELD EPL-SHIELD

Wires are to be twisted pair.With a minimum of one (1)twist per 25.4mm [1.00 in] perSAE-J1708. Wires must be wrapped using drain wire with foil shield for the full length of the wires. Drain wire is not to be exposed to theenvironment. Splice crosslink approximately 76.2mm [3.00 in] from endto noninsulated drain wire.See J1939 Section.For EPL Link, use Belden Cable P/N 85231 or equivalent.

All wires are to be 16 AWG GXL per SAE J-1128

J2 J1

Z

VIEW Z - Z

A

B

C

D

E

F

G

HJ

K

L

M

NPEPL Connector

J3

Z

1005-11-97

Typical Transmission Interface Harness

31


With an ohmmeter, check the resistance from Pins E & L to the battery negative post.Resistance should not be more than 0.5 ohms.

1028-11-97

Main Logic Ground

ECU CONNECTOR WIRE TABLESHIFT LEVER 24-WAY CONNECTORWIRE DESCRIPTION PIN LOCATIONSL_GND B1

TRANSMISSON INTERFACE CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONTRAN_GND E & L

Floor Board

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


C

B

A

D

E

M

G

KJ

H

L

F

NP

ECU CONNECTOR WIRE TABLESystem Manager 24-Way ConnectorWIRE DESCRIPTION PIN LOCATIONSYS_GND B8 & B7

B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1


12 11 10 9 8 7 6 5 4 3 2 1

131415161718192021222324

Transmission Controller 24-Way Connector

ECU CONNECTOR WIRE TABLETransmission Controller 24-Way Connector

WIRE DESCRIPTION PIN LOCATIONTRAN_GND 2, 11, 12, & 14

32

ElectricalSystem

RequirementsMain Logic Power (+12 Volts)

Main Logic Power is supplied to each ECU through the power connect relay located in theshift tower.

1029-11-97

ECU CONNECTOR WIRE TABLESHIFT LEVER 24-WAY CONNECTORWIRE DESCRIPTION PIN LOCATIONSL_VBATT A2

TRANSMISSON INTERFACE CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONTRAN_VBATT D & K

Floor Board

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12


ECU CONNECTOR WIRE TABLESystem Manager 24-Way ConnectorWIRE DESCRIPTION PIN LOCATIONSYS_VBATT A9 & B9

B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1


12 11 10 9 8 7 6 5 4 3 2 1

131415161718192021222324

Transmission Controller 24-Way Connector

ECU CONNECTOR WIRE TABLETransmission Controller 24-Way Connector

WIRE DESCRIPTION PIN LOCATIONTRAN_VBATT 1 & 13

C

B

A

E

M

G

KJ

H

L

F

NP

D

33


Power Connections

J28

J29

Power Interface Module Mounted onTransmission next to ECU.

1030-10/93

1010-10/93

Red

The main power and ground leads for the AutoSelectTM and AutoShift™ must be con-nected to the starter by the OEM.

The Packard connector J29 will supply logic power to all three ECU's. This connectorwill run into the shift tower. Connector J28 is the motor supply connection to thetransmission ECU.

Main vehicle battery cable (+) or (-) must be disconnected prior to any type of weldingon any AutoSelectTM or AutoShiftTM equipped vehicle.

THIS VEHICLE IS EQUIPPED WITH ELECTRONICCONTROLS. THE FOLLOWING PRECAUTIONS

MUST BE TAKEN WHEN WELDING:• DISCONNECT THE MAIN VEHICLE BATTERY CABLE (+)

AND (-) AND ANY ELECTRONIC GROUND WIRESCONNECTED TO THE FRAME OR CHASSIS.

• COVER ELECTRONIC CONTROL COMPONENTS ANDWIRING TO PROTECT FROM HOT SPARKS, ETC.

• DO NOT CONNECT WELDING CABLES TO ELECTRONICCONTROL COMPONENTS.

CAUTION

Truck Components

+

-

34

SAE J1939 Recommended Cable Termination Procedure1. Remove cable outer jacket approximately 25mm.

2. Remove foil from exposed wires to within 2mm from cable jacket.

3. Strip insulation from data wires 7mm.

4. Attach extended wire barrel socket contact to the drain wire or attach adhesive fillersolder sleeve and wire to drain wire per manufacturer’s recommendation.

5. For the solder sleeve option, cut the wire on the solder sleeve to a length of 25mmand strip the insulation back 7mm.

6. Crimp the appropriate terminal on each data wire and the solder sleeve wire OR theextended socket per the manufacturer’s recommendations.

7. Slide an adhesive filler shrink tube over the cable end.

8. Install the terminals into the connector body per the manufacturer’s instructions.

9. Install the wedge in the front of the connector body per the manufacturer’s instruc-tions.

10. Apply the shrink tube to the end of the connector body per the manufacturer’srecommendation.

Existing Drain Wire Splice / Sealing Method

ElectricalSystem

Requirements

AutoShift ™Only

Mechanical Connection

DATA LINK CABLE

Non-Insulated Drain Wire 16 Gage GXL Cross-Linked(Approximately 3 Inches)

DATA LINK CABLE

Double Walled Shrink Tube

DATA LINK CABLE

Double Walled Shrink Tube

NOTE: Shrink Tube is Adhesive Filled 1036-4-97

35


AutoShift™ Only

ENGINEECM

SYSTEMMANAGER

OPTIONALMODULES

A

B

C

D

E

F

Ref. Body Signal Terminals (QTY) Shield Terminal (QTY)

A

G

A AA A

A

A

B

B

B

BB

Wedge

CC

C D

DT06-3S-E008

DT06-3S-E008

DT04-3P-P007

DT04-3P-P006

DT04-3P-E008

DT04-3P-LE08

Function

Through Connector

Stub Connector

"T" Receptacle

120 Ohm Termination

120 Ohm Termination

ECU Receptacle

Flang Receptacle

0462-201-1631 (3) **

0462-201-1631 (3) **

N/A

0460-202-1631 (3) **

0460-202-1631 (3) **

0462-221-1631 (1) **

0462-221-1631 (1) **

0460-247-1631 (1) **

0460-247-1631 (1) **

W3S-1939

W3S

N/A

N/A

N/A

N/A

N/A

W3P

W3P

G DT06-3S-P006 N/A N/A N/A

** If an additional wire is added to the drain for insertion into the connector, no shield terminal is used and the signal terminal quantity is 3. If the drain wire is to be directly inserted into the connector, then a shield terminal is used and the signal terminal quantity is 2.

F

F

E

Shield Termination16 Gage GXL

Recommended Cable Manufacturer

Cable Part Number Round

J1939 (+)(PIN "A")Color

J1939 (-)(PIN "B")Color

J1939(PIN"C")Shield

Champlain

Champlain

Raychem

Raychem

Raychem

BICC Brand-Rex

23-00013-001

23-00028-001

2021D0311

2021D0001

2021D0301

T-14945

Yes

Yes

Yes

No

No

No

Yellow

Yellow

Yellow

Yellow

Yellow

Yellow

Green

Green

Green

Green

Green

Green

N/A

N/A

N/A

N/A

N/A

N/A

Shield TerminationJ1939 (+)

J1939 (-)J1939 Shield

1.00 MeterMax Length



J1939 "Backbone" Communication Harness

36

ElectricalSystem

Requirements

ECU CONNECTOR WIRE TABLESystem Manager 32-Way ConnectorWIRE DESCRIPTION PIN LOCATIONJ1939-HIGH

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12


FIREWALL/ATA CONNECTOR WIRE TABLE

WIRE DESCRIPTION PIN LOCATIONJ1939-HIGH GJ1939-LOW H

PIN LOCATIONFirewall ATA Connector

AB

C

B

A

D

N

M

G

HJ

K

L

F

EP

J1939-LOWC5C4D13 D14 D15 D16

C13 C14 C15 C16

J-1939 WIRE TABLEWIRE DESCRIPTION PIN LOCATIONJ1939-HIGH

J1939-LOW

A

B

J1939-SHIELD C

J1939-SHIELD D5

J1939-SHIELD J C

A

B

C

J1939 "Backbone" Interface Harness

1039-11-97

37

AutoShift ™Only

Location of the J-1939 Control Data Link on All CaterpillarElectronic Engines

20041A-1-97

20040-6-93

19

1 2 3 4 5 6

7

13

23

29

22

12

18

28

34

35 36 37 38 39 40

J1939-SHIELD

J1939 (+)

J1939 (-)

DESCRIPTION

J1-33

J1-39

J1-26

J1939 (+)

J1939 (-)

J1939 Shield

J1

See Connector Information Sectionfor specific details on the J1939 connector and secondary lock.J1939 approved wire must be used.


38

Location of the J-1939 Control Data Link on Detroit DieselDDECIII Engines

Electronic Control Module (ECM)

CommunicationConnector

20046-6/93

20046a-6/93

AutoShift™ Only

INTERCONNECTION TABLEFROMCONN. LABEL

NO.

J5-F J1939+

J5-E J1939-

J5-D J1939 SHIELD

J1939 Wire Must Be Used

J5

ElectricalSystem

Requirements

39


Location of the J-1939 Control Data Link on Cummins Engines

20046a-6/93

As a part of the Cummins ECM Interface Harness, The J1939 3-Pin Deutch connectorwill already be present. No additional connections are needed to connect the EngineECM to the J1939 “BACKBONE”.

NOTE: It may be necessary to extract the connector from behind a bracket located at therear of the engine. Simply push the connector out from behind the bracket.

EngineECM

Engine

40

The checklist was developed as an installation tool for line personnel to ensure thecorrect operation of each vehicle and to assist the vehicle OEM to identify transmissionquality related issues as well as OEM line quality issues. Used correctly, this checklistidentifies 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 an AutoSelectTM/AutoShiftTM transmission. If these checks and information can be combined with anexisting form the "Line Inspection Form" (4013-002) does not have to be used.

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

3. At this point the checklist should be reviewed and if necessary corrective actiontaken prior to the dyno or road test.

4. The DYNO/ROAD TEST section is used to verify that all transmission systems arefunctional, the clutch is adjusted properly, and to ensure the driver information issupplied in the cab.

5. The OEM now has a record of transmission related information and repairs made toeach unit and is able to track and correct repeated quality issues.

6. A copy of the checklist should be supplied to Eaton Customer Quality Group forinstallation history. OEM line personnel should become familiar with the checklistand download procedures for the transmission prior to a scheduled build. EatonCustomer Quality Group can coordinate training and information to expedite thisprocess.

This checklist represents a generic system which can be tailored to the individual OEM toachieve the best possible method of transmission installation verification. Eaton recom-mends the use of this system to maintain the utmost in satisfactory operation and longservice life.

Each AutoSelectTM and AutoShiftTM system installed at the OEM must pass the on-linechecklist requirements per the Eaton Line Inspection Form 4013-002 prior to shipmentfrom the OEM plant.

LineInspection

41

Refer to the Line Inspection Form, Appendix IV, while performing the following procedure.All information must be filled in at form top.

Pre-Start Checks1. The following tests must be performed in one of three ways:

A. By visually observing the power up procedure. This is the preferred test.

B. By visually verifying the harness connections.

C. By checking the pins at the service port. A standard volt/ohm meter is needed.

Ignition Bus check:

A. Turn on the key switch and visually observe the Driver Command Console. Does the servicelight turn on and tone sound? If yes, there is ignition power to the transmission. If no, use thevolt/ohm meter and check the pins in the service port as stated in step C. If the correct voltage isfound on Pins A and D, there is a vehicle wire harness problem.

B. Verify that the service port pin A is connected to the ignition bus.

C. Use a volt/ohm meter, touch the black lead to pin D and the red lead to pin A. The volt meterreading should be equal to battery voltage (power with key on only).

Power Connect Relay check:A. Turn on the key switch and visually observe the Gear Display. Does the Gear Display Modulelight-up? If yes, the power connect relay is installed correctly. If no, use the volt/ohm meter andcheck the pins in the service port as stated in step C. If the correct voltage is found, contact theEaton Customer Quality Group. If the correct voltage is not found on pins C and D, there is avehicle wire harness problem.

B. Verify the service port pin C is connected to the normally open power connect relay contact.

C. Using a volt/ohm meter, touch the black lead to pin D and the red lead to pin C. The volt meterreading should be equal to the battery voltage (power with key on only).

2. Visually verify that the transmission ignition power supply is protected by an automatic resettingcircuit breaker, 10AMP/12 VDC Ignition Bus.

NOTE: Only perform the next step, Step 3, on each vehicle with a new wiring configuration.

3. Verify latching diode installed across start enable relay: place the shift handle in neutral, apply theparking brakes, block the wheels, and remove the access panel on the Shift Tower. Disconnect theSystem Manager ECU 24-Way (J4) connector located inside the shift tower. Turn the key and holdin the start position; if the vehicle is equipped with a start button, hold button in the start position.With a jumper wire, short across Service Port pins A and E. When the starter begins cranking,remove the jumper. If the latching diode is correctly installed, the engine will continue to crank. Ifthe engine stops cranking when the jumper is removed, refer to the Start Enable Relay Harnessinformation for correct latching diode installation instructions. After test, replace the SystemManager ECU 24-Way (J4) connector and the Shift Tower access cover.

4. Oil Fill - Verify the transmission has been filled with the correct amount (see Lubrication Require-ments) and type of oil before starting the engine. Failure to add sufficient oil could damage thetransmission. Use Eaton‚ Roadranger‚ CD50.

5. End-of-Line Programming (refer to End-of-Line Transmission Application Programming Informa-tion). The following programming requirements must be completed prior to driving the vehicleof the line or dyno test.

LineInspection

Checklist Instructions

42

A. Execute the download program on the PC.

B. Enter the required information for the specific vehicle application.

C. The configuration file automatically download to the transmission system.

D. Record the configuration number on the inspection form.

Dyno/Road Test6. With the engine not running, place the shift handle in DRIVE and attempt to start the

engine. Repeat for each of the forward and reverse gear positions to verify the engine willnot start.

7. Verify correct clutch adjustment and correct pedal free travel per clutch manufacturer’sspecifications.

8. Verify that all forward and reverse gears can be obtained. Note: High range reverse isselected by engaging reverse and then pressing the up arrow on the lever. The down arrowwill re-engage low range. Note also that some dynamometers decelerate too quickly forgears 1 through 4 to be obtained. When this occurs, select DRIVE and press the up arrowon the shift lever to select 5th gear start. The transmission should shift up and downnormally from 5th gear. If shifting trouble still exists, drive the vehicle on the road. If thetransmission shifts correctly, the problem is with the deceleration rate of the dynamometerand not with the transmission.

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

10. Visually verify that the gear display module is easily visible and lights up when the ignitionis turned on. Note: When testing on a dynamometer which decelerates quickly, the displaymodule may appear to not function correctly. Should this occur, drive the vehicle off thedynamometer and note what the display does. If it functions correctly when driving, theproblem is that the dynamometer decelerates to quickly.

11. Verify through normal operation that the engine brake functions (if equipped) correctly perthe manufacturer’s specifications (Mechanically Governed Engines Only).

12. Verify that the panel lights on the shift lever light up when the vehicle panel light is turnedon. This can also be checked out with a volt meter - touch the black lead to pin D of theservice port and the red lead to pin B of the service port. The voltage reading should varywith the dimmer control (with dash lights on only).

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

14. Make sure that the correct transmission dash label is present and that the driver’s instruc-tion booklet is included with the other vehicle information.

15. Verify the transmission diagnostic port (SAE-J1587) is accessible, either mounted on thedash left side or just under the dash left side.

16. Verify that a label to alert the customer of type and brand of oil used on the transmission isattached to the transmission or included with the other vehicle information.

17. Clear historical fault codes by using the ignition key switch. To do this, place the shift leverin Neutral and set the parking brakes. Begin with the key in the ON position. Turn the keyoff and back on six times within five seconds. (OFF/ON/OFF/ON/OFF/ON/OFF/ON/OFF/ON/OFF/ON)

Codes can also be cleared using the Hand-Held Diagnostic Tool. Some vehicles areequipped with more than one J-1587 diagnostic connector. All diagnostic connectors mustbe checked to make sure they are functional.

LineInspection

43

LineInspection

Line Inspection Form

! WARNINGTransmission equipped with a neutral interlock system thatwhen properly installed prevents engine starting with thetransmission in-gear.

Failure to ensure installation pre-start checks may result inthe engine cranking immediately when ignition is moved tothe "START" position or to the "ON" position.

To prevent undesired vehicle movement for new installa-tions, always set the parking brake and depress the masterclutch pedal fully prior to turning the ignition key "ON" andalso prior to attempting "START".

Depress the master clutch pedal fully and set parkingbrakes before starting engine.

If gear display fails to stop flashing after 5 seconds, turnkey off and check clutch adjustment.

44

OEMChassis S/NTrans Model # Trans S/NClutch Size/TypeShift Tower S/NDo not record the following numbers, if the Shift Tower S/N has been recordedSystem Manager S/NDCC S/N

AUTOSELECTTM

AUTOSHIFTTM

Line Inspection

✓

Form 4013-002

Description Yes No Corrected

Pre-Start Checks1. Power Supply checks:

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

Power Connect Relay check: Does Gear Display Module light up?

2. AutoSelectTM or AutoShiftTM Circuit Breaker / Fuse

10 amp/12 VDC Ignition Bus (auto reset type) or 10 Amp Fuse

3. Verify latching diode installed across Start Enable Relay correctly.

A. Transmission must be in neutral. NOTE: First time installation only.

4. Oil Fill - 26 pints (12.3 liters) Eaton® Roadranger® CD50

5. Program AutoShiftTM with PC Configuration #_____________________

DYNO/Road Test Checks6. Verify engine does not start with transmission in gear

7. Correct clutch free travel and adjustment

8. All forward and reverse gears obtained

9. Verify transmission temperature gauge functional—if equipped

10. Verify gear display module (DDM) works correctly

11. Verify engine brake works correctly (if equipped)—AutoSelectTM Only

12. Shifter panel light functional

13. Verify no transmission oil leaks

14. Verify AutoShiftTM shift label and drivers instructions book in cab

15. Transmission diagnostic port accessible

16. Oil type & brand affixed to vehicle

17. Clear Fault Codes and Verify J1587 Diagnostic Connector works

Comments

Final Inspection Date Please send copy to: Eaton Corp. FAX # (616) 383-5520

Signature P.O. Box 4013, Kalamazoo, MI 49003 Attn. Autom. Prod. Dept. 94

All gears display and dim when dashlights are turned on

45

TroubleshootingGuide

Troubleshooting

Check for properair pressure.

Check for properoil level.

Check transmission power circuit.(fuses, circuit breakers)

NO YES

Is the transmission performing properly?

For low air; verify air system.For low oil level; check lube requirements.For power; reset/replace fuses, circuit breakers andverify the connection at the starter location.

NO YES

Do any of the following conditions exist? Resume operation.

NO YES

Call OEM service help.

Service light on solidor flashing. Wait Light on Engine does not crank, Engine cranks

in any lever position, Engine stopscranking for no reason.

Refer to TroubleshootingGuide for flash code retrieval.Call OEM service help.

Verify Start Enable relay circuit isinstalled correctly. Measure resistanceat service port across pins D & E.Result should be 45-90 Ohms. Verifycontacts are connected correctly inthe safety neutral circuit. Verifylatching diode is connected correctly.Verify transmission is not torque locked and push

in the clutch. If Wait Light is still on, then powerdown: turn key off and wait for 1 minute. Push inthe clutch, power up.

Is the transmission performing properly?

NO YES

Resume operation.Call OEM service help: Eaton Corp./CustomerQuality Group—(616) 342-3000.

46

EATON AUTOMATED Transmissions

47

Operating Temperatures with Oil Coolers

The transmission should not be operated consistently at temperatures above 250°F.However, intermittent operating temperatures to 300°F do not harm the transmission.Operating temperatures above 250°F increases the lubricant’s oxidation rate and short-ens its effective life. When the average operating temperature is above 250°F, thetransmission will require more frequent oil changes or external cooling.

The following conditions in any combination can cause operating temperatures of over250°F: (1) Operating consistently at slow speeds. (2) High ambient temperatures, (3)Restricted air flow around transmission, (4) Exhaust system too close to transmission,(5) High horsepower operation.

External oil coolers are available to reduce operating temperatures when the aboveconditions are encountered.

Transmission Oil Coolers are:

Recommended— With engines of 350 H.P. and above

Required— With engines 399 H.P. and above and GCW’s over 90,000 lbs.

— With engines 399 H.P. and above and 1400 Lbf·ft or greater torque

— With engines 450 H.P. and above

Proper Lubrication Levels as Related to Transmission Installation Angles

If the transmission operating angle is more than 12 degrees, improper lubrication canoccur. The operating angle is the transmission mounting angle in the chassis plus thepercent of upgrade (expressed in degrees).

For example: if you have a 4 degree transmission mounting angle, then 8 degrees (or 14percent of grade) is equal to the limit of 12 degrees. If you have a 0 degree mountingangle, the transmission can be operated on a 12 degree (21 percent) grade. Anytime thetransmission operating angle of 12 degrees is exceeded for an extended period of timethe transmission should be equipped with an oil pump or cooler kit to insure properlubrication.

NOTE: The chart shows the effect an oil level 1⁄2" below normal can have on safe operat-ing angles. Operating the vehicle 1⁄2" low on oil reduces the safe degree of grade byapproximately 3 degrees (5.5 percent).

Oil Cooler Chart12

10 19'

10 13'

9 16'

8

6 51'

5 48'

4 35'

3 26'

2 18'

1 8'

00 1 2 3 4 5 6 7

22

20

18

16

14

12

10

8

6

4

2

0

Transmission Mounting Angle

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

Proper Lubrication Levels are Essential!

Per

cen

t G

rad

e C

on

vert

ed t

o D

egre

es

Lim

itat

ion

s fo

r P

rop

er L

ub

rica

tio

ns

Per

cen

t o

f G

rad

e

TRANSMISSION OIL LEVEL 1/2" BELOW FILLER HOLE

2 QUARTS LOW

TRANSMISSION OIL LEVEL TO BOTTOM OF FILLER HOLE

12°11° 20'

ApplicationInformation

48

Appendix I

Gear Display Module(Suggested Location)Diagnostic/Interface

Port (SAE J-1587)AccessibleIn Cab

Vehicle Instrument Panel

Firewall Bulkhead ConnectorFor Vehicle Harness

Shift Tower

SystemManagerECU

Bulkhead Style HarnessConnector Through Cab FloorReinforced

Cab Floor

AutoSelectTM

/AutoShiftTM

Main Power and GroundSupplied From VehicleStarter Posts

Transmission To VehicleInterface HarnessesVehicle Harness

Firewall To Shift Tower

Transmission Power SupplyHarness From Starter

TransECU Transmission Harness

Transmission To Shift Tower

Transmission ECU

TransmissionWire Harness

AutoSelectTM

/AutoShiftTM

Transmission

ShiftTower

SW

LOGI

C

SYSM

AN

COM

MSY

SMAN

SERV

ICE

VEHI

CLE

RELA

Y

TRAN

SMIS

SION

DCC

Shift Lever

SystemManagerECU

1019-10/93

System Overview(Typical Truck Application)

49

Appendix I

System Overview(Typical Bus Application)

SHIFT LEVER

SYSTEM MANAGER ECU

LOCATED IN AC BOX

AUTOSHIFT TRANSMISSION

J-1939 DATA LINK(AUTOSHIFT ONLY)

POWER CONNECT RELAY

START ENABLE RELAYLOCATED IN REAR JUNCTION BOX

GEAR DISPLAY

1035-6-94

D HOLD LHR N

A B C A B C

50

Appendix II

Tower Assembly Connectors

1009-3-97

Deutsch 14-Way Connector(Vehicle Interface Harness)

HD34-18-14PN0460-202-16141

ConnectorTerminal

HD34-18-14SN0460-201-16141

ConnectorTerminal

SW

LOGI

C

SYSM

AN

COM

MSY

SMAN

SER

VICE

VEHI

CLE

REL

AY

TRAN

SMIS

SION

DCC

Deutsch 14-Way Connector(Transmission Interface Harness)

Power Connect RelayService Port Connector

51

Appendix II

Packard 32-Way Connector12041476120896491204588912045890

Mating ConnectorTerminal Secondary Lock Secondary Lock



D HOLD LHR N

A B C

A B C




Mating ConnectorTerminal Secondary Lock

Shift Lever Connectors

System Manager ECU Connectors

52

Appendix II

Deutsch 14-Way ConnectorPackard 6-Way Connector12124107120457731204808612052850

Body Terminal Cable Seal Secondary Lock

BodyTerminalCavity Plug

HD36-18-14PN0460-202-16141114017

Deutsch 14-Way ConnectorPackard 6-Way Connector12124107120457731204808612052850

Body Terminal Cable Seal Secondary Lock

BodyTerminalCavity Plug

HD36-18-14PN0460-202-16141114017

See J1939 BACKBONE information for connectordetails relating to J4.

J2 J1

EPL Connector

J3

Deutsch 3-Way ConnectorDT04-3P-E0080460-202-16310460-247-1631W3P

Body Signal PinsShield Pin (If Used)Wedge

J2 J1

J1939 Connector

J4

EPL Connector

J3

Deutsch 3-Way Connector

(2) Deutsch 14-Way Connectors

HD36-18-14SN0462-201-16141114017

ConnectorTerminal Cavity Plug

J1 J2

If a wire is soldered to the drain, use signal pin. If thedrain wire is to inserted directly,use Shield Pin.

If a wire is soldered to the drain, use signal pin. If thedrain wire is to inserted directly,use Shield Pin.

DT04-3P-E0080460-202-16310460-247-1631W3P

Body Signal PinsShield Pin (If Used)Wedge

Transmission Interface Harness (AutoSelect™) Connectors

Transmission Interface Harness (AutoShift™) Connectors

Vehicle Interface Harness Connectors

53

Appendix II

TruckComponents

EATON P/N4302640

J33

TopView

4 3 2 1

J33 = Body Amp 1-480702-0 Terminal Amp 350551-2

A B

CDE

F

ATA = Body Deutsch HD10-6-12P Terminal Deutsch 0460-220-1213 Cap Deutsch HDC 16-6

ATA = Body Amp A-206433-4 Terminal Amp A-205201-5 Strain Relief Amp A-206062-1 Cap Amp A-208800-1

SAE has 2 approved connectors, Eatonrecommends the Deutsch 6 pin connector shown above.

Deutsch Connector Amp Connector

ATA Connector

Gear Display Connector

54

Appendix II

Transmission Sensor Position - Top

1025-1-97

Do Not RemoveCapscrew

Location forReverse

Ball Switch(OEM Supplied)

Do Not RemoveCapscrew

Tower AssemblyInterface Connector

12:00 (Top) Output Shaft

Speed Sensor

Power Leads Connected to Starter(12 Volt Starter Only)

EPL Connector

55

Transmission Sensor Position - Left

1026-1-97

Power Leads Connected to Starter(12 Volt Starter Only)

6:00 (Bottom)Output Shaft

Speed Sensor

LO Diagnostic Port(out of view, other sideof Range Cylinder)

Tower AssemblyInterface Connector

HI Diagnostic Port

EPL Connector

Appendix II

56

1024-1-97

Transmission Controller Connectors

Appendix II

24-WayConnector(J3)

32-WayConnector(J1)

Gear SelectConnector

Rail SelectConnector

Motor SupplyConnector Power Interface

Module

NOTE: The Transmission Controller Harness is supplied by Eaton when the transmission is shipped. The OEM is not responsible for supplying any part of this harness. If any of these connectors are damaged during shipment, please contact your Eaton representative for replacement information. The Wiring Diagrams show how each wire is connected.

57

Appendix II

19

1 2 3 4 5 6

7

13

23

29

22

12

18

28

34

35 36 37 38 39 40

J1939-SHIELD

J1939 (+)

J1939 (-)

J1

Deutsch Body AEC16-405Terminal

J1

See J1939 BACKBONE for Connector Information

See J1939 BACKBONE for Connector Information

0460-201-16141

NOTE: The J1 Caterpillar Connector should already be present.

J1939-SHIELD

J1939 (+)J1939 (-)F

EDCBA


BodyTerminal Plug

Caterpillar J1939 Connector

Detroit Diesel J1939 Connector

58

Appendix III

Torque Specificationsa. Flywheel capscrews:

follow engine manufacturer's specifications

b. Transmission-to-engine capscrews:

inch design (7⁄16-14) - 37-50 Lbf·ft*inch design (3⁄8-16) - 25-32 Lbf·ft*metric design (M10-35) - 26-35 Lbf·ft*

c. Transmission nodal mount capscrews: (3⁄4-10 UNC) - 180-190 Lbf·ft

d. Output yoke nut - 450-500 Lbf·ft

e. PTO mounting bolts:

6-bolt opening - 20-25 Lbf·ft*

8-bolt opening - 50-65 Lbf·ft*

f. Reverse switch - (9⁄16-18) - 20-25 Lbf·ft

g. Neutral switch/cap - (3⁄4-16) - 20-25 Lbf·ft

h. Driver Command Console - (1⁄4-20) - 8-14 Lbf·ft

i. Speedometer electronic sensor (3⁄4-16) - 10-15 Lbf·ft

j. Oil fill plug (11⁄4 NPT) - 60-75 Lbf·ft

k. Oil drain plug (3⁄4 NPT) - 45-55 Lbf·ft

l. Lifting bracket capscrews (3⁄8-16) - 35-45 Lbf·ft

m. Rear support stud nuts (5⁄8-18) - 170-185 Lbf·ftUse lockwashers

n. Mainshaft rear bearing cover capscrews (3⁄8 - 16) - 35-45 Lbf·ft

o. Range Air Value Mtg. Screw - (#10-24) 21-27 Lbf·in

*THREAD ADHESIVE/SEALANT REQUIRED

59

Vendor List

AMP Incorporated(Connectors)P.O. Box 3608Harrisburg, PA 17105-36081-800-522-6752

BELDEN WIRE AND CABLE(EPL and J-1939 Cable)P.O. Box 1980Richmond, IN 47375(317) 983-5200

BRAND-REX CO.(J-1939 Cable)1600 West Main StreetWillimantic, CT 06226-1128(203) 456-8000

CHAMPLAIN CABLE CO.(J-1939 Cable)12 Hercules Dr.Colchester, VT 05446(802) 655-2121Fax (802) 654-4224

DEUTSCH(Connectors)Industrial Products Division37140 Industrial Ave.Hemet, CA 92545(909) 765-2250

Appendix IV

PACKARD ELECTRIC(Connectors)Pioneer-Standard Electronics, Inc.Packard Branch5440 Naiman ParkwaySolon, OH 441391-800-PACKARD

RAYCHEM(Wire)Deanco Inc.Meag Division25W 624 St. Charles RoadWheaton, IL 60188(708) 665-6214

ROBERT BOSCH CORPORATION(Relays)2800 South 25th AvenueBroadview, IL 60153(708)865-5301

60

Quick ReferenceEngine SectionA. Clutch Requirements

Spring Dampened clutches required for all applications.B. Transmission Mounting

• Space requirements for transmission mounted electronics are 4" from any high temperature devices (i.e. Exhaust Crossover Pipes).• Mounts to standard #1 clutch housing, same as standard mechanical boxes.• Possible clutch arm to transmission ECU interference during installation, clutch

arm removal may be required.• Transmission shipped in-gear for input shaft to clutch alignment• Transmission prop shaft installation - axles must rotate to allow indexing of

attachment hardware.• Eaton approved oil to water oil cooler required for 18 speed transmissions.

C. Electronically Governed Engines• Can not be programmed for progressive shifting.

Chassis SectionD. Electronic vehicle speedometer must be used (options available for both push-in and

thread-in electronic speed pickups (provisions for two 3⁄4-16 electronic speed pick-ups)).

E. Vehicle Air dryer required.F. Transmission oil - Eaton Roadranger CD50 or equivalent synthetic required.

Electrical SectionG. Electrical Dual Power required

• Main power and ground leads connected to the starter.• OEM to supply main vehicle harness (dash to driver command console).

H. Diagnostic Connector required• Diagnostic J-1587 connector mounted in or under dash on left side of cab.

I. J-1939 Data Link (AutoShift only) OEM must supply J-1939 Backbone HarnessJ. Latching Diode across start enable relay required

• Latching mechanism in starter circuit to allow uninterrupted power during start-up.

• Diode must be a 1N4007 or equivalent.

Appendix V

61

Appendix V

System ManagerK. The system manager ECU chassis must be connected to chassis ground

through its chassis mounting hole or by the chassis ground wireprovided in the tower assembly.

Cab SectionL. Driver Command Console (shift control) required

• Shift control installed per Eaton approval• Wire harness routing per Eaton approval• OEM is responsible for rigidly mounting the shift tower assembly.• Access plate on floor board is easily removable.

Aluminum Plates should be 0.250” thick or greaterSteel Plates should be 0.125” thick or greater.

• Sealed connectors required at shift tower on conventional cabs.• If console mounted system used, OEM responsible for cab harness

connecting System Manager to Driver Command Console, PowerConnect Relay, Service Port, and Transmission.

M. Gear Display Module Supplied by Eaton• Digital display mounts in dash to provide driver information.

63

GearSelectSensor

A

B

C

A

B

C

RailSelectSensor

A

B

C

A

B

C

A

B

A

B

ReverseBall Switch

A

B

A

B

A

B

A

B

A

B

A

B

Input ShaftSpeed Sensor

Output ShaftSpeed Sensor

Main ShaftSpeed Sensor

HI

LO

RangeValve

A

B

C

A

B

C

InertiaBrake

Solenoid

A

B

A

B

Transmission 32-w

ay Connector

Transmission 24-W

ay Connector

14

13

27

28

11

12

1

2

16

17

18

19

20

21

29

30

31

12

13

1

2

14

10

3

4

7

8

9

24

23

11

RailSelectMotor

GearSelectMotor

A

B

A

B

B

A

25 AMP

15 AMP

A B

A B

TRAN

SMISSIO

N C

ON

TRO

LLER

A A

B B

C C

A A

B B

C C

D D

E E

F F

EPL data linkEPL data link

D14

C1

D13

C13

C9

D9

C8

D8

D7

D11

C2

D1

C5

C4

D5

30 87 87a 85 86

Power Connect Relay

87 87a

30

85

86

SystemManager

ECU

System M

anager 32-Way C

onnector Syst

em M

anag

er 2

4-W

ay C

onne

ctor

A1

A3

A10

A9

B9

B7

A6

B4

B8

C B A

C B A

UP

DOWN

B8 B7 B6 B5 B4 B3 A1 A2 B1 A10 B2 A3 B10 B11 A8 A9 A12

SHIFT LEVERShift Lever 24-Way Connector

A

B

C

D

M

E

F

J

G

L

A

B

C

D

M

E

F

J

G

L

Gear Display

123 4

FCB EFCB E

FCB E

Converter

12 Volts

24 Volts

Gear DisplayOld Style

Gear Display

Backside of

Gauges

DashLights


C

A

B

E

+12Volts For Transmission diagnostics

8787a

30

85

86

LatchingDiode

1N4007

StartEnableRelay

Run to StartSignal from

Igntion Switch

Run toStarter Solenoid

Ignition Power(Switched Power)

Run to Main Power Lead ThatFeeds the Ignition Bus

10 AMP 12 Volt onlyAutomatic Resetting

Circuit Breaker

10 AMP Fuseor

AB

C

DE

F

A

B

C

D

M

E

F

J

G

L

A

B

C

D

M

E

F

J

G

L

CONNECT TOSTARTER

Power Interface module

G D C B A F E

Service Port

Transmission Harness


(OEM supplied)

Tower Harness

VehicleInterfaceHarness

(OEM supplied)

DashHarness

(OEM supplied)

All OEM responsible wiring shown is "typical". Consult specific application.+12 volt non-switched from battery+12 volt switched from Power Connect Relay+12 volt switched from Ignition SwitchSignals into the ECUCommunication from and to the ECUSignal returns, Grounds, and general OEM wiring+12 volt solenoid source

Wheel Chair Liftsee OEM for wiringdiagrams and correct operation.

Engine ECM

A

B C

TerminatingResistor Terminating

Resistor

J1939 Data Link(OEM supplied)

Battery+ _

ShieldTermination

J193

9 da

ta li

nk

J1587 data link

AutoShift Wiring Diagram

A

B

C

M

L

K

D

E

F

G

H

J

N

P

A

B

C

M

L

K

D

E

F

G

H

J

N

P

HI

LO

SplitterValve

B

C

A

B

C

A

4

1

2

3

5

8

Note: A Splitter valve is used for 18 speed applications only.A Connector is capped for 10 speed applications.

64

GearSelectSensor

A

B

C

A

B

C

RailSelectSensor

A

B

C

A

B

C

A

B

A

B

ReverseBall Switch

A

B

A

B

A

B

A

B

A

B

A

B

Input ShaftSpeed Sensor

Main ShaftSpeed Sensor

Output ShaftSpeed Sensor

HI

LO

RangeValve

A

B

C

A

B

C

InertiaBrake

Solenoid

A

B

A

B

Transmission 32-w

ay ConnectorTransm

ission 24-Way Connector

14

13

27

28

11

12

1

2

16

17

18

19

20

21

29

30

31

12

13

1

2

14

10

3

4

7

8

9

24

23

11

RailSelectMotor

GearSelectMotor

3

4

5

8

1

2

A

B

A

B

B

A

25 AMP

15 AMP

A B

A B

TRANSMISSION CONTROLLER

A A

B B

C C

A A

B B

C C

D D

E E

F F

EPL data linkEPL data link

D14

C1

D13

C13

C9

D9

C8

D8

D7

D11

C2

D1

C5

C4

D5

30 87 87a 85 86

Power Connect Relay

87 87a

30

85

86

SystemManager

ECU

System M

anager 32-Way Connector Sy

stem

Man

ager

24-

Way

Con

nect

or A1

A3

A10

A9

B9

B7

A6

B4

B8

C B AC B A

UP

DOWN

B8 B7 B6 B5 B4 B3 A1 A2 B1 A10 B2 A3 B10 B11 A8 A9 A12

SHIFT LEVERShift Lever 24-Way Connector

A

B

C

D

M

E

F

J

G

L

A

B

C

D

M

E

F

J

G

L

Gear Display

123 4

FCB EFCB E

FCB E

Converter

12 Volts

24 Volts

Gear DisplayOld Style Gear Display

Backside ofGauges

DashLights


CABE

+12Volts For Transmission diagnostics

8787a

30

85

86

LatchingDiode

1N4007

StartEnableRelay

Run to StartSignal from

Igntion Switch

Run toStarter Solenoid

8787a

30

85

86

Optional EngineBrake Disable

Relay

Run to Throttle Switch

Run toClutch Switch

Ignition Power(Switched Power)

Run to Main Power Lead ThatFeeds the Ignition Bus

10 AMP 12 Volt onlyAutomatic Resetting

Circuit Breaker

10 AMP Fuseor

AB

C

DE

F

A

B

C

D

M

E

F

J

G

L

A

B

C

D

M

E

F

J

G

L

CONNECT TOSTARTER

Power Interface module

G D C B A F E

Service Port

Transmission Harness


(OEM supplied)

Tower Harness

VehicleInterfaceHarness

(OEM supplied)

DashHarness

(OEM supplied)

All OEM responsible wiring shown is "typical". Consult specific application.+12 volt non-switched from battery+12 volt switched from Power Connect Relay+12 volt switched from Ignition SwitchSignals into the ECUCommunication from and to the ECUSignal returns, Grounds, and general OEM wiring+12 volt solenoid source

Wheel Chair Liftsee OEM for wiringdiagrams and correct operation.

J1587 data link

AutoSelect Wiring Diagram

A

B

C

M

L

K

D

E

F

G

H

J

N

P

A

B

C

M

L

K

D

E

F

G

H

J

N

P

HI

LO

SplitterValve

B

C

A

B

C

A

** Connector is capped for 10 speed applications.

**

Fo r spec’ing or service assistance, call 1-80 0-826-HELP (4357) 24 hours a day, 7 days a w eek (Mexico:

001-80 0-826-4357), for mo re time on the road. O r visit our w eb sit e at www .roadr ang er.com .

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

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

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

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

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Installation Guide - Roadranger