Guia de Instalacion EATON FULLER PDF

Fuller Heavy Duty Transmissions
More time on the road
Installation Guide
Fuller Heavy Duty Transmissions
TRIG0070
October 2007
RTLO-11610B
RTLO-16618A
RTLOC-16909A-T2
RTLOF-16618A
RTLO-11610B-T2
RTLO-16713A
RTLOF-11610B
RTLOF-16713A
RTLO-12610B
RTLO-16713A-T2
RTLOF-11610B-T2
RTLOF-16713A-T2
RTLO-12610B-T2
RTLO-16718B
RTLOF-12610B
RTLOF-16718B
RTLO-12713A
RTLO-16913A
RTLOF-12610B-T2
RTLOF-16913A
RTLO-12913A
RTLO-16913A-T2
RTLOF-12713A
RTLOF-16913A-T2
RTLO-13610B
RTLO-16918B
RTLOF-12913A
RTLOF-16918B
RTLO-13610B-T2
RTLO-16918B-T2
RTLOF-13610B
RTLOF-16918B-T2
RTLO-14610A
RTLO-17610B
RTLOF-13610B-T2
RTLOF-17610B
RTLO-14610B
RTLO-17610B-T2
RTLOF-14610B
RTLOF-17610B-T2
RTLO-14610B-T2
RTLO-18610B
RTLOF-14610B-T2
RTLOF-18610B
RTLO-14613B
RTLO-18610B-T2
RTLOF-14613B
RTLOF-18718B
RTLO-14618A
RTLO-18718B
RTLOF-14618A
RTLOF-18913A
RTLO-14713A
RTLO-18718B-T2
RTLOF-14713A
RTLOF-18913A-T2
RTLO-14718B
RTLO-18913A
RTLOF-14718B
RTLOF-18918B
RTLO-14913A
RTLO-18913A-T2
RTLOF-14913A
RTLOF-18918B-T2
RTLO-14918B
RTLO-18918B
RTLOF-14918B
RTLOF-20913A
RTLO-14918B-T2
RTLO-18918B-T2
RTLOF-14918B-T2
RTLOF-20918B
RTLO-15610B
RTLO-20913A
RTLOF-15610B
RTLOF-20918B-T2
RTLO-15610B-T2
RTLO-20918B
RTLOF-15610B-T2
RTLOF-22918B
RTLO-16610B
RTLO-20918B-T2
RTLOF-16610B
RTLOFC-16909A-T2
RTLO-16610B-T2
RTLO-22918B
RTLOF-16610B-T2
Warnings and Cautions

The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any
time without notice.
Important Notice
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use
and should not be considered an endorsement. Equivalents may be used.
WARNING
This symbol is used throughout this

manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.
Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.
Failure to follow indicated

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

procedures may cause component
damage or malfunction.
IMPORTANT
Highly recommended procedures for

proper service of this unit.
Note: Additional service information not
covered in the service procedures.
Tip: Helpful removal and installation
procedures to aid in the service of this unit.
Always use genuine Eaton replacement parts.

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

General Information
How to Use This Manual ............................................1
Installation Requirements
Requirements .............................................................2
Space Requirements ..................................................3
10-speed Valve Location ........................................3
9- / 13-speed Valve Location ..................................5
18-speed Valve Location ........................................6
Lubrication Requirements ..........................................8
Air Supply Requirements ..........................................10
9-speed Pneumatic Diagrams ...............................11
10-speed Pneumatic Diagrams .............................12
Transmission Mounting Requirements ....................15
Mounting Transmission to Engine ........................16
Using Rear Supports ............................................17
Typical Rear Support Designs ...............................17
Electrical Requirements
Top 2 Valve Electrical Requirements ........................ 18
Wiring Diagram OEM Responsibility ........................ 19
Caterpillar Programming ...................................... 19
Detroit Diesel Programming ................................. 21
Line Inspection
Line Inspection and Road Test Instructions ............. 26
Line Inspection Form ............................................... 27
Troubleshooting ....................................................... 28
Appendix
Wiring Diagrams ...................................................... 29
Caterpillar ............................................................. 29
Detroit Diesel ........................................................ 31
Torque Specifications .............................................. 33
Suggested Tools ...................................................... 34
Related Publications ................................................ 34
Application Forms .................................................... 35
Table of Contents
Warnings and Cautions ...............................................i
General Information
How to Use This Manual

This Eaton Publication is intended to be a reference guide for the installation of all Top 2 series transmissions. As much general
vehicle and transmission information has been given for covering the wide range of applications. This information benefits the
OEM installer by providing the correct installation procedures to ensure the utmost in satisfactory operation and long service life.
For specific engine information, contact engine OEM.
Specific OEM installation requirements are shown in each section.
Failure to adhere to Eaton installation requirements may effect transmission performance and/or warranty coverage.
Top 2 transmissions installed at OEM facilities must meet the requirements for standard manual Eaton Fuller transmissions outlined in Form FUL-169. Applications outside of these requirements must be approved by Eaton Engineering using Form FUL-170.
All information contained in this manual was accurate at the time of printing. With each new application, engine manufacturers
should be contacted to make sure desired engines are compatible with the Top 2 system.
Requirements
All Top 2 transmission systems installed at OEM facilities must meet the requirements for standard manual Eaton Fuller
Transmissions outlined in Form FUL-169 and be approved using the Eaton Automated Transmission Application
Approval Form FUL-170. Both forms can be found in the Appendix.
Air Dryer Requirements - A high quality commercially available vehicle air dryer is required to be used in conjunction
with Top 2 systems.
2.
Clutch Requirements - Spring dampened clutches are required for all applications.
3.
Electrical Requirements - All wires are to be a minimum of 16 gauge GXL.
4.
Integral Coolers - Reference Form FUL-169 Note 2 for transmission cooler requirements.
5.
Line Inspection - All Eaton Top 2 transmission systems installed at OEM plants must pass the requirements outlined in
the Line Inspection Form prior to shipment.
6.
Lubrication Requirements - Transmission oil should meet specifications as outlined in TCMT-0020 (Roadranger Products Approved Lubricants) and TCMT-0021 (Roadranger Products Lubrication Manual).
7.
Power Connections - All ECMs will have redundant power and ground pins. If no redundancy is available, a relay connection similar to the one on page 29.
8.
Valve Spatial Requirements - The Top 2 solenoid valve requires a minimum of 2 clearance from any high temperature
devices (i.e. exhaust crossover pipes).
Installation
Requirements
1.
Space Requirements
10-speed Valve Location
Note: Refer to Transmission Mounting Requirements for Valve Spatial Requirements.
Installation
Requirements
MODEL
LENGTH A
LENGTH B
LENGTH C
11610
815.1 (32.09)
200.4 (7.89)
67.8 (2.67)
12610
815.1 (32.09)
200.4 (7.89)
67.8 (2.67)
13610
815.1 (32.09)
200.4 (7.89)
67.8 (2.67)
14610
823.2 (32.41)
208.5 (8.21)
75.9 (2.99)
15610
823.2 (32.41)
208.5 (8.21)
75.9 (2.99)
16610
823.2 (32.41)
208.5 (8.21)
75.9 (2.99)
9- / 13-speed Valve Location

LENGTH A
LENGTH B
LENGTH C
12713
815.1 (32.09)
200.4 (7.89)
43.9 (1.73)
14713
823.2 (32.41)
208.5 (8.21)
51.8 (2.04
16713
823.2 (32.41)
208.5 (8.21)
46.5 (1.83)
12913
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
14913
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
18913
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
Installation
Requirements
MODEL
18-speed Valve Location

MODEL
LENGTH A
LENGTH B
LENGTH C
14918
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
16918
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
18918
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
20918
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
22918
840.7 (33.09)
226.1 (8.9)
69.6 (2.74)
Lubrication Requirements
Eaton Fuller transmissions are designed so the internal parts operate in a bath of lubricant circulated by the motion of gears and
shafts. Thus, all parts will be amply lubricated if these procedures are closely followed:
Use Roadranger CD50 or equivalent E500 synthetic per Eaton publication TCMT-0021.
When adding lubricant, types and brands of lubricant should not be mixed because of possible incompatibility.
Use clean lubricant and clean containers when filling the transmission. Containers that have been used for antifreeze or
water should not be used for transmission lubricant.
Additives and friction modifiers are not recommended for use in Eaton Fuller transmissions.
Recommended Lubricant
Type
Grade (SAE)
Temperature
Roadranger CD50
Transmission Fluid
50
ALL
Includes all Roadranger Approved comparable synthetic lubricant.
Proper Lubricant Level

Transmission Capacity
9-Speed
28 pints (13.2 liters)
10-Speed
13/18-Speed
Note: Failure to adhere to Eaton Installation Requirements may effect transmission performance and /or warranty coverage.
Note: The quantity for proper fill level will vary from model to model.
Make sure lubricant is level with fill hole opening. Because you can reach lubricant with your finger does not mean lubricant is at
the proper level. (On heavy duty transmissions, one inch of lubricant level equals about 8 pints of oil).
Hole
Improper Oil Level
Hole
Proper Oil 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.
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).
Proper Lubrication Levels are Essential!
22
12o
11o 20'
TR
AN
20
SM
IS
SI
ON
18
10o 13'
OI
LL
EV
EL
TR
AN
SM
IS
14
TO
9o 16'
BO
TT
OM
SI
ON
12
OI
LL
2Q
FI
EL
RT
6o 51'
LL
EV
UA
10
8o
OF
1/
2"
LO
ER
HO
LE
BE
5o 48'
LO
FI
4o 35'
LL
ER
HO
LE
3o 26'
2o 18'
1o 8'
0o
1o
2o
3o
4o
5o
6o
Percent Grade Converted to Degrees
Limitations for Proper Lubrications

Percent of Grade
16
0o
7o
Transmission Mounting Angle

Dotted line showing "2 Quarts Low" is for reference only.
Not recommended.
Note: For transmissions with coolers installed, make sure lubricant is level with fill hole opening, run the truck, stop and check
lubricant level. Lubricant must be level with fill hole.
Air Supply Requirements

It is required to use a high quality commercially available air dryer in the air supply line before the transmission.
2.
Minimum air requirement for the transmission is 65 PSI.
3.
A minimum of 1/4 diameter air supply line is required.
4.
The transmission air supply is required to be routed from the air tank, which supplies air to either the front or rear 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
CAUTION
Do not tie wrap air line

to wire harness on transmission
10
Installation
Requirements
1.
9-speed Pneumatic Diagrams

Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
Roadranger
valve
HI Range Inactive
LO Range Pressured
5/32" or 1/8" air line
HI Range Pressured
LO Range Inactive
5/32" or 1/8" air line
Constant regulated
air (55-65 PSI)
S
5/32" air line
Air filter/
regulator
Top 2
Solenoid
Valve
P1
5/32" air line

HI Split Pressured
LO Split Inactive
S
L
1/4" air hose
HI Range Inactive
LO Range Pressured
1/4" air hose

S
Constant regulated
air (55-65 PSI)
1/4" air hose
Constant regulated
air (55-65 PSI)
Range
Cylinder
Splitter
Cylinder
1/4" air hose
Lock High
Except During
Top 2 Function
11
5/32" air line
EXH
P2
H
Slave
Valve

Installation
Requirements
12

13

Installation
Requirements
14
Transmission Mounting Requirements

Handling
Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components.
1.
Use a hoist or transmission jack that permits precise control of transmission movement during installation.
Transmission Preparations
Always remove banding and protective wrapping from the transmission and inspect for shipping damage as soon as possible
upon receiving.
2.
If a thread-in electronic speedometer system is used, tighten sensor or sensor lock nut to 35 lbs-ft. [47 Nm], (3/4-16
threads). If a push-in electronic speedometer system is used, Eaton P/N 14142 (O-ring) and Eaton P/N 71206 (silicon
lubricant) are used to seal the sensor.
3.
To remove, reposition, or replace rear bearing cover, apply Eaton Sealant P/N 71205 or equivalent to threads and tighten
main shaft rear bearing cover capscrews to 35-45 lbs-ft. [47-61 Nm] (3/8-16).
Output Yoke/Flange Installation

Note: The output yoke/flange is supplied with the transmission. If the output Yoke/flange must be replaced, the following procedure should be followed. (For detailed instructions, refer to the proper transmission model service manual.)
Select the proper output yoke per specified application, remove plastic cover, and inspect the slinger (gold anodized ring) and
seal surface for damage or contamination. Do not use the yoke/flange if the slinger or seal surface is damaged such as dents,
nicks, or scratches.
15
1.
Prior to installation, remove all contamination such as styrofoam particles, dust, dirt, or rust in the machined surface of
the yoke/flange.
2.
Place the yoke/flange over the transmission output shaft end and rotate it to line up the splines. Take care not to bump
any machined surface of the yoke/flange against the output shaft. Push the yoke all the way onto the output shaft and
onto the seal with one continuous motion.
3.
Thread the tail shaft nut onto the tailshaft until nylon insert is engaged on the tailshaft thread. Secure yoke/flange and
tighten the tailshaft nut to 450-500 lbs-ft. [610-678 Nm].
Mounting Transmission to Engine

Use the two transmission lifting eyes provided. The lifting eye position must not be changed on the transmission.
Note: For lifting eye and sensor retaining bolt locations, see Appendix. These bolts can not be used for brackets or for any other
purpose.
Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs.
2.
Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure engine flywheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of
damage before installation.
3.
Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmission must be in gear in order to rotate the input shaft by turning the output shaft/yoke.
4.
Adjust the lift chain or transmission jack to obtain the same relative angle as the engine. The face of the engine flywheel
housing and the face of the transmission clutch housing must be parallel during installation. If the transmission is properly aligned and the clutch is installed properly, very little force is required to slide the input shaft through the clutch and
into the pilot bearing.
5.
If interference is encountered, move the transmission away from the engine to investigate the cause. The use of excessive force to overcome misalignment may cause damage to the transmission input shaft and the clutch.
6.
Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines.
7.
Once the transmission is seated against the engine flywheel housing, align the clutch housing bolt holes with the engine
flywheel housing bolt holes and install all capscrews and tighten finger tight.
Note: The clutch housing must be flush against the engine flywheel housing before tightening any capscrews. Do not use the
capscrews to seat housing.
8.
Tighten four capscrews at 90 intervals around the clutch housing, then tighten the remaining transmission mounting
capscrews using the recommended torque specifications.
Note: Do not tighten any mounting capscrews until all capscrews have been installed and finger tightened. Do not remove the
transmission support chain or jack until all mounting bolts have been tightened.
16
Installation
Requirements
1.
Using Rear Supports

The OEM is responsible for determining if rear transmission support is required.
1.
The transmission nodal mounting pads are approved to be used as a rear engine support location.
2.
The OEM is responsible for nodal mount design.
3.
Torque transmission nodal mount capscrews (3/4-10 UNC) to 180-190 lbs. ft. [224-258 Nm] of torque
Typical Rear Support Designs
17
Top 2 Valve Electrical Requirements
Mating connector description:
J1
Description
Part Number
Quantity
Connector Body
12110293
Cable Seal
12048086
Terminal
12048074
Secondary
12052845
Electrical
Requirements
Designation
18
Wiring Diagram OEM Responsibility

Caterpillar Programming
Note: All information on this page is only for a Caterpillar engine.
End-of-Line Programming at the OEM

Caterpillar units will already be programmed with all known features. The features simply need to be enabled. The VEPS software allows the OEM to activate / deactivate features.
Programming at the Distributor Site

Contact your Caterpillar representative for programming instructions.
Service Tool ET (Electronic Technician) allows for the activation of the Eaton Top 2 Transmission Style parameter.
Once the Eaton Top 2 is activated, gear ratios must be programmed as well. Each ratio must be programmed to three decimal
places. Those ratios are as follows:
Transmission Model
Top Gear Minus

Two Ratio
Top Gear Minus

One Ratio
Top Gear Ratio
RTLO-XX610B-T2
1.352
1.000
0.741
RTL-XX710B-T2
RTL-XX910B-T2
1.825
1.351
1.000
RTLO-XX713A-T2
RTLO-XX913A-T2
1.000
0.856
0.730
RTLO-XX718B-T2
RTLO-XX918B-T2
1.000
0.856
0.730
RTLOC-1X909A-T2
1.000
0.856
0.730
Note: XX appearing in the transmission model number refers to the XX x 100 = Nominal Torque Capacity. For example,
RTLO-14610B-T2 has a nominal torque capacity of 14 x 100 or 1400 lbs. ft.
Multi-function Output #7 is programmed as the Shift Solenoid in the Output Selections Group.
Multi-function Output #6 is programmed as the Lockout Solenoid in the Output Selections Group.
Caterpillar recommends locking out all Eaton Top 2 related parameters after programming has been completed and proper operation has been verified.
Note: After parameters have been locked out, Factory Passwords are required to edit.
19
Caterpillar Schematic Diagram
19
20
Interconnection Table
From Top 2
Solenoid Valve
To Engine Control
Module Connector (P1)
Description
19
Lockout
none
Engine Ground Stud
20
Shift
Electrical
Requirements
Caterpillar Wiring Diagram
20
Detroit Diesel Programming

Note: All information on this page is only for a Detroit Diesel engine.
End-of-Line Programming at the OEM

DDEC units will already be programmed with all known features. The features simply need to be enabled. The VEPS software
allows the OEM to activate / deactivate features or configure individual ECM pins. VEPS can assign any ECM pin to a specific
function, as long as the physical function of the pin is compatible. Usually this is automatic with VEPS software, but can be
assigned manually as well. This method is used after order entry when the required features are known.
Programming at the Distributor Site

DDEC units are programmed with all features and are setup in a similar fashion to the End-of-Line Programming. The distributor
programming station will download the latest software version from the DDC mainframe. The distributor will trace back the wires
from the Top 2 solenoids and manually enter in the individual pin numbers as assigned to the Top 2 Lock-Out Solenoid and the
Top 2 Shift Solenoid drivers which then activates the Top 2 feature.
For further information, contact your Detroit Diesel representative.
Programming Information:
DDEC III and IV

Circuit Name
SID
Pin
Connection
Auxiliary Output #1
26
F-3
OEM Vehicle Interface Connector
Auxiliary Output #2
40
A-2
Auxiliary Output #5
53
W-3
Top 2 3-Way Connector
Auxiliary Output #6
54
X-3
Auxiliary Output #7
55
Y-3
Auxiliary Output #8
56
A-1
Diagnostic tools can verify the configuration of the solenoids with functional identifiers that are noted below.
The Lockout solenoid is given a functional identifier of 31.
The Shift solenoid is given a functional identifier of 30.
While Eaton recommends the use of Auxiliary Output 5 (W-3) as Lockout and the use of Auxiliary Output 7 (Y-3) as Shift,
any two of the above outputs can be used.
DDEC V
Circuit Name
SID
Pin
Connection
Digital Output
40
V-5
Digital Output
53
V-6
21
DDEC III and IV Schematic Diagram
Electrical
Requirements
Select two of the available six Auxiliary Outputs for use as Lockout and Shift.
These two selected pins must be noted and used during the programming of the ECM.
22
DDEC V Schematic Diagram
Dig Output (V-5)

Dig Output (V-6)
23
DDEC III, IV and V Wiring Diagram
Electrical
Requirements
Typical DDEC III and IV System Overview
Top 2 Valve
ECM DDEC III & IV
Vehicle Interface
Connector
24
Typical DDEC V System Overview
Top 2 Valve
ECM DDEC V
DDEC III and IV ECM Harness Connector
Pins available for selection through engine sensor pigtail harness: W-3, X-3, and Y-3.
Note: Any two of the six pins listed may be used for Lockout and Shift. After deciding which two pins will be used, refer to the
End-of-Line Programming information based on your engine type, to complete the programming of the ECM.
DDEC V ECM Harness Connector

46
31
16
25
10
25
55
26
11
61
30
15
64
Pins available for selection: A-1, A-2, and F-3.
40
56
41
60
45
65
68
DDEC III and IV OEM Vehicle Interface Connector
Line Inspection
Line Inspection and Road Test Instructions

Refer to the Line Inspection Form while performing the following procedure:
1.
2.
Power Supply Checks:
DDEC - Visually verify the power connections at the battery bus through a 10 amp circuit breaker or fuse.
Caterpillar - Visually verify the ground connection between the solenoids and truck.
Cummins - Visually verify the ground connection between the solenoids and truck.
Oil Fill:
3.
Verify the transmission has been filled with the correct amount of oil and type before starting engine. Failure to add
sufficient oil could damage the transmission. Use Eaton Roadranger CD50 or equivalent as specified in TCMT-0021
the Roadranger Product Lubrication Manual on the www.Roadranger.com Literature Center.
End-of-line Programming
See page 19, page 21, page 29, or page 31 depending on your engine type.
Dyno / Road Test

4.
Verify correct clutch adjustment and correct pedal free travel per clutch manufacturers requirements.
5.
Verify through normal operation that all transmission forward and reverse gears can be obtained. Verify transmission
makes automatic shifts in lever position AUTO.
6.
Visually check for oil drips or residue on the transmission and related cooler lines, if used.
7.
Make sure that the correct transmission dash label is present and that the drivers instruction booklet is included with
the other vehicle information.
8.
Verify that a label to alert the customer of type and brand of oil used in the transmission is attached tot the transmission
or included with other vehicle information.
9.
Clear fault codes in the engine ECM. Refer to OEM engine literature.
26
Line Inspection
Line Inspection
Line Inspection Form

Inspection Sheet
TOP 2
Line Inspection
Oem
Chassis S/N
Trans Model #
Description
Trans S/N
Yes
Pre-Start Checks
1.
2.
Power Supply check:

Oil Fill - Eaton Roadranger
DYNO/ROAD TEST CHECKS

Correct clutch free travel and adjustment
All forward and reverse gears obtained
(Including Automatic Shifting Gears)
6. Verify no transmission oil leaks
7. Verify Top 2 shift label
Drivers Instructions book in cab
8. Oil type & brand affixed to vehicle
9. Clear Fault Codes in Engine ECM
Comments
4.
5.
Final Inspection Date

Signature
Please send copy to: Eaton Corp. FAX #(269) 383-5520 ATTN: Automation Installations Group
or mail copy to : Eaton Corp, 13100 E. Michigan Ave., Galesburg, MI 49053 ATTN: Automation Installations Group
27
No
Corrected
Line Inspection
Troubleshooting
Check for proper air pressure.
See Pneumatic Air Diagrams.
Check for proper lube level.

See Lubrication Requirements.
Check transmission power circuits.

See Schematic Diagrams for fuse
and ground information.
Line Inspection
Functional?
Resume operation.
YES
NO
When Shift Lever is in the "AUTO"

position, the transmission does not
make any automatic shifts. Manual
splitter shifts are normal.
The Splitter Button does not work,

however, the transmission does
make shifts in the "AUTO" position.
The Splitter Button does not work

and the transmission does not make
automatic shifts in the "AUTO"
position.
When Shift Lever is in the "AUTO"

position, the transmission does not
make any automatic shifts. Manual
splitter shifts are normal.
The Splitter Button does not work,

however, the transmission does
make shifts in the "AUTO" position.
The Splitter Button does not work

and the transmission does not make
automatic shifts in the "AUTO"
position.
Call the Roadranger Call Center

at 1-800-826-HELP (4357).
Functional?
NO
Resume operation.
YES
28
OFF C
ON
S
START
R
6.5mA
H795-PK
E971-GN
A/C HIGH PRESS. SWITCH N/C
H795-PK
40mA
5mA
10A
PASSIVE
MAGNETIC
VEHICLE SPEED
SENSOR
G808-BU
G809-GN
COOLING FAN SOLENOID
10A
ENGINE RETARDER
SOLENOID SELECTOR SWITCH
E717-GN
NOTE C
NOTE F
SIGNAL-
SIGNAL+
C973-GN
TO CHASSIS J1939 DATA LINK
E793-BU
E794-YL
A249-BK
K990-GN
K900-YL
NOTE B
NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION

TO THE BATTERY IS NOT REQUIRE
100mA
100mA
P1 J1
28 CHECK ENGINE LAMP

29 WARNING LAMP
30 OUTPUT #1
31 OUTPUT #9
70 IGNITION KEY SWITCH
62 INPUT #12
64 INPUT #13
61
36 SPEEDOMETER POSITIVE
37 SPEEDOMETER NEGATIVE
10 OUTPUT #2
12 OUTPUT #3
13 OUTPUT #4
15
16
38 TACHOMETER POSITIVE
39 TACHOMETER NEGATIVE
18 INPUT SENSOR COMMON #1
47 INPUT #5 (NOTE L)
6 INPUT #6 (NOTE L)
57
27 INPUT #9
J1587 DATA LINK NEGATIVE
9
J1587 DATA LINK POSITIVE
8
42 J1939 DATA LINK SHIELD (NOTE K & NOTE M)
34 J1939 DATA LINK NEGATIVE (NOTE K & NOTE M)
50 J1939 DATA LINK POSITIVE (NOTE K & NOTE M)
1
14
26 INPUT #10
48 UNSWITCHED +BATTERY (NOTE D)
63 -BATTERY
65 -BATTERY
67 -BATTERY
3 INPUT SENSOR COMMON #2
17 INPUT #14
C453-YL
35 SET
44 RESUME
993-BR
59 CRUISE CONTROL ON/OFF SWITCH
7 INPUT #4 (NOTE L)
45 SERVICE BRAKE PEDAL POSITION SWITCH
11 OUTPUT #5
19 OUTPUT #6
20 OUTPUT #7
21 OUTPUT #8
22 CLUTCH PEDAL POSITION SWITCH
43
23 RETARDER SOLENOID LOW/HI SWITCH
2
+5V
49 ENGINE COOLANT LEVEL NORMAL (NOTE G)
54 ENGINE COOLANT LEVEL LOW (NOTE G)
40 RETARDER SOLENOID MED/HI SWITCH
51
55
24 INPUT #15 POSITIVE
25 INPUT #15 NEGATIVE
32 VEHICLE SPEED IN POSITIVE (NOTE F)
33 VEHICLE SPEED IN NEGATIVE
69
5 ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMO
4 +8V
66 ACCELERATOR PEDAL POSITION
P2 J2
VEHICLE HARNESS CONNECTOR
G845-PU
H795-PK
C985-BU
C986-BR
E971-GN
G834-PU
G835-OR
G808-BU
G809-GN
E716-GY
G879-OR
C983-WH
C984-YL
E717-GN
F713-OR
C978-BR
C979-OR
K999-GN
K980-PK
C975-WH
K982-YL
G841-GN
C992-PU
G837-YL
G838-BR
G839-BU
G840-PU
C977-BU
101-RD
101-RD
101-RD
229-BK
229-BK
229-BK
G933-YL
E793-BU
E794-YL
A249-BK
K990-GN
K900-YL
450-YL
451-BR
L901-GY
G842-GY
G843-OR
G844-PK
C974-PU
C973-GN
E718-PK
E991-GY
G836-WH
L994-YL
659-PK
K998-BU
G880-PK
J906-BR
G881-BU
G882-WH
NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE

MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
1
2
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
451-BR
450-YL
NOTE B
0.3A CURRENT LIMIT
0.3A CURRENT LIMIT
C974-PU
TACHOMETER
NOTE E
NOTE H
SIGNAL-
SIGNAL+
659-PK
L994-YL
TO +BATTERY
NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE
TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM
VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER
SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER.
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED,
THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS
DO NOT CONNECT TO GROUND
OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37,
J1-38, AND J1-39 IS +/-10 VOLTS. AMPLITUDE WILL BE
+/- 5 VOLTS
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED
OR GREATER IF LOAD CURRENT IS LESS THAN 4mA.
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED
ACCELERATOR PEDAL
POSITION SENSOR
BK
B
H795-PK
RD
A
C985-BU
WH
C
C986-BR
J403 P403
MED
HI
LO
MED
HI
LO
E716-GY
C978-BR 6.5mA
C979-OR 6.5mA
SET/RESUME
10A
+BATTERY
-BATTERY
B
A
J
H
G
J1587 DLINK
ATA NEGATIVE
J1587 DLINK
ATA POSITIVE
F
E
J1939 DATA LINK Shield
J1939 DATA LINK Negative D
J1939 DATA LINK Positive
C
RETARDER SOLENOID ON/OFF SWITCH

NOTE H
13mA
C977-BU 6.5mA
CLUTCH PEDAL POSITION N/C
SPEEDOMETER
NOTE E
NOTE H
WARNING LAMP
CHECK ENGINE LAMP
SAE J1939/13 OFF-BOARD

DIAGNOSTIC CONNECTOR
SERVICE BRAKE PEDAL POSITION N/C

6.5mA
C992-PU
H795-PK
H795-PK
(PEDAL RELEASED POSITION)
C975-WH
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON

+8 V
ACCELERATOR PEDAL POSITION
6.5mA NOTE H
BATTERY 1
- 12V+
TO VEHICLE
COMPONENTS
NOTE D
NOTE D
CRUISE CONTROL ON/OFF
H795-PK
H795-PK
ENGINE
BLOCK
BATTERY 2
BATTERY 3
NOTE J
- 12V+
STARTER
MOTOR
(12V)
BAT MTR
- 12V+
GROUND
ALTERNATOR
KEY SWITCH
45.5mA MAX
29
N/O
RELAY
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
Appendix
Wiring Diagrams
Caterpillar
C11, C13, C15, and C18 OEM Diagrams (2003)
OFF C
ON
S
START
R
- 12V+
C978-BR 6.5mA
C979-OR 6.5mA
SET/RESUME
H795-PK
E971-GN
NOTE D: THESE CONNECTIONS ARE UNSWITCHED, DIRECT CONNECTION

TO THE BATTERY IS NOT REQUIRED
NOTE C: "SINGLE" WINDING MAGNETIC PICKUP SENSOR RECOMMENDED
NOTE B: FOR SPEEDOMETERS OR TACHOMETERS WITH A SINGLE SIGNAL INPUT

TERMINAL, EITHER ONE OF THE TWO SIGNAL OUTPUT LINES FROM
THE ECM CAN BE USED. LEAVE THE REMAINING LINE DISCONNECTED,
DO NOT CONNECT TO GROUND
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED
ACCELERATOR PEDAL
POSITION SENSOR
40mA
5mA
SIGNAL-
SIGNAL+
C973-GN
G808-BU
G809-GN
COOLING FAN SOLENOID
10A
PASSIVE
MAGNETIC
VEHICLE SPEED
SENSOR
10A
TO CHASSIS J1939 DATA LINK
E793-BU
E794-YL
A249-BK
K990-GN
K900-YL
NOTE B
100mA
100mA
G845-PU
H795-PK
C985-BU
C986-BR
P1 J1
28
29
30
31
70
62
64
61
36
37
10
12
13
15
16
38
39
18
47
6
46
57
27
9
8
42
34
50
1
14
26
48
52
53
63
65
67
3
17
35
44
56
58
59
60
7
45
11
19
20
21
22
43
23
2
49
54
40
51
55
41
24
25
32
33
69
68
5
4
66
P2 J2
NEGATIVE
POSITIVE
SHIELD (NOTE K & NOTE M)
NEGATIVE (NOTE K & NOTE M)
POSITIVE (NOTE K & NOTE M)
INPUT #8 (NOTE L)
+8V
INPUT #11 (NOTE L)

INPUT #15 POSITIVE
INPUT #15 NEGATIVE
VEHICLE SPEED IN POSITIVE (NOTE F)
VEHICLE SPEED IN NEGATIVE
RETARDER SOLENOID LOW/HI SWITCH

+5V
ENGINE COOLANT LEVEL NORMAL (NOTE G)
ENGINE COOLANT LEVEL LOW (NOTE G)
RETARDER SOLENOID MED/HI SWITCH
INPUT #10
UNSWITCHED +BATTERY (NOTE D)
-BATTERY
-BATTERY
-BATTERY
INPUT SENSOR COMMON #2
INPUT #14
C453-YL
SET
RESUME
993-BR
INPUT #1 (NOTE L)
INPUT #2 (NOTE L)
CRUISE CONTROL ON/OFF SWITCH
INPUT #3 (NOTE L)
INPUT #4 (NOTE L)
SERVICE BRAKE PEDAL POSITION SWITCH
OUTPUT #5
OUTPUT #6
OUTPUT #7
OUTPUT #8
CLUTCH PEDAL POSITION SWITCH
INPUT #9
J1587 DATA LINK
J1587 DATA LINK
J1939 DATA LINK
J1939 DATA LINK
J1939 DATA LINK
TACHOMETER POSITIVE
TACHOMETER NEGATIVE
INPUT SENSOR COMMON #1
INPUT #5 (NOTE L)
INPUT #6 (NOTE L)
INPUT #7 (NOTE L)
SPEEDOMETER POSITIVE
SPEEDOMETER NEGATIVE
OUTPUT #2
OUTPUT #3
OUTPUT #4
CHECK ENGINE LAMP

WARNING LAMP
OUTPUT #1
OUTPUT #9
IGNITION KEY SWITCH
INPUT #12
INPUT #13
VEHICLE HARNESS CONNECTOR
E971-GN
G834-PU
G835-OR
G808-BU
G809-GN
E716-GY
G879-OR
C983-WH
C984-YL
E717-GN
F713-OR
C978-BR
C979-OR
K999-GN
K980-PK
C975-WH
K982-YL
G841-GN
C992-PU
G837-YL
G838-BR
G839-BU
G840-PU
C977-BU
101-RD
101-RD
101-RD
229-BK
229-BK
229-BK
G933-YL
E793-BU
E794-YL
A249-BK
K990-GN
K900-YL
450-YL
451-BR
L901-GY
G842-GY
G843-OR
G844-PK
C974-PU
C973-GN
E718-PK
E991-GY
G836-WH
L994-YL
659-PK
K998-BU
G880-PK
J906-BR
G881-BU
G882-WH
NOTE F: IF AN ELECTRONIC SIGNAL IS PROVIDED IN PLACE OF A PASSIVE

MAGNETIC SENSOR, CONNECT THE ELECTRONIC SIGNAL INPUT TO
THE +SIGNAL PIN, THE -SIGNAL PIN SHOULD NOT BE CONNECTED
OR GROUNDED WITH ELECTRONIC SIGNAL INPUTS
1
2
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
14 AWG GXL
451-BR
450-YL
NOTE B
0.3A CURRENT LIMIT
0.3A CURRENT LIMIT
C974-PU
TACHOMETER
NOTE E
NOTE H
SIGNAL-
SIGNAL+
659-PK
L994-YL
TO +BATTERY
NOTE E: THE ECM SPEEDOMETER AND TACHOMETER OUTPUT SIGNAL LINE

VOLTAGES ARE ZERO-CROSSING SQUARE WAVES. THE SPEEDOMETER
SIGNALS AT J1-37 AND J1-36 ARE COMPLEMENTS OF EACH OTHER.
THE TACHOMETER SIGNALS AT J1-38 AND J1-39 ARE COMPLEMENTS
OF EACH OTHER. MAXIMUM SIGNAL AMPLITUDE OF J1-36, J1-37,
J1-38, AND J1-39 IS +/- 10 VOLTS. AMPLITUDE WILL BE +/- 5 VOLTS
OR GREATER IF LOAD CURRENT IS LESS THAN 4mA.
B
BK
H795-PK
A
RD
C985-BU
C
WH
C986-BR
J403 P403
NOTE C
NOTE F
10A
+BATTERY
-BATTERY
B
A
J
H
J1587 DATA LINK NEGATIVE G
J1587 DATA LINK POSITIVE F
E
J1939 DATA LINK Shield
D
J1939 DATA LINK Negative
J1939 DATA LINK Positive
C
RETARDER SOLENOID ON/OFF SWITCH

NOTE H
13mA
C977-BU 6.5mA
A/C HIGH PRESS. SWITCH N/C
H795-PK
H795-PK
SPEEDOMETER
NOTE E
NOTE H
WARNING LAMP
CHECK ENGINE LAMP
SAE J1939/13 OFF-BOARD

SERVICE BRAKE PEDAL POSITION N/C

H795-PK
C992-PU 6.5mA
C975-WH 6.5mA
CLUTCH PEDAL POSITION N/C
H795-PK

+8 V
6.5mA NOTE H
BATTERY 1
- 12V+
TO VEHICLE
COMPONENTS
NOTE D
NOTE D
CRUISE CONTROL ON/OFF
NOTE J
BATTERY 2
- 12V+
STARTER
MOTOR
(12V)
BAT MTR
H795-PK
ENGINE
BLOCK
BATTERY 3
GROUND
ALTERNATOR
KEY SWITCH
45.5mA MAX
N/O
RELAY
Appendix
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
Appendix
C15 OEM Diagrams (2004)
30
31
RED/BLK
BLK
WHT
GRA
A-3
C-3
K-3
A-1
916
952
979
988
440
953
COOLANT LEVEL PROBE

3/8 in. NPT
DDC P/N: 23520381
1/4 in. NPT
DDC P/N: 23520380
9/16 in. UNF
DDC P/N: 23522855
CONNECTOR
P/N: 12034074
TERMINAL
P/N: 12089040
IGNITION
CONNECTOR
D A
E C
ECM
POWER
CONNECTOR
+12/24VDC
419
509
150
240
D
A
* FUSE
COLOR-RED
(2) CABLES
REQ'D.
953
(-)
BATTERY
NEGATIVE
IGNITION
FUSE
COLORBLACK
(4) CABLES
REQ'D.
CRIMP WIRES INTO

SINGLE CONNECTOR
AT BATTERY ONLY
12 OR 24
VDC SUPPLY
NOTE:
* FUSES OR CIRCUIT BREAKERS ARE TO BE LOCATED AS CLOSE TO THE
BATTERY AS PRACTICAL AND MUST BE HOUSED WITHIN WEATHERPROOF
HOLDER.
USE WATERPROOF SPLICES TO SPLICE 12 GA. WIRES TO
APPROPRIATE WIRE GAUGE CABLES FROM BATTERY POWER.
440
STOP ENGINE LIGHT RED

RD
CHECK ENGINE LIGHT YELLOW

YE
(+)
BATTERY
POSITIVE
PPL/WHT
PPL
USE 12 AWG WIRE NOT TO

EXCEED 14 FEET IN LENGTH.
150
150
E
B
241
CONNECTOR
P/N: 12124634
TERMINAL
P/N: 12077413
CABLE SEAL
P/N: 12015193
SECONDARY LOCK
WIRE
P/N: 12052816
CAVITY NO.
30 WAY CONNECTOR
DDC P/N: 12034398
TERMINAL
DDC P/N: 12103881
PLUG
DDC P/N: 12034413
INSTRUMENT PANEL
WIRE NO. COLOR
POWER HARNESS SINGLE ECM SINGLE FUSE
All information subject to change without notice. (Rev. 8/03)

7SA743 0308 Copyright 2003 DETROIT DIESEL CORPORATION.
280 SERIES
METRI-PACK
CONNECTOR
DDC P/N: 15300027
TERMINAL
DDC P/N: 12077411
CABLE SEAL
DDC P/N: 12015323
SECONDARY LOCK
DDEC P/N: 15300014
COLOR
ORN
BLK/WHT
F
G
H
J
K
A
B
* DIGITAL INPUTS AND DIGITAL OUTPUTS

ARE PROGRAMMABLE BY THE OEM
1 2 3
IGNITION
BLK/WHT
ON
OFF
953
DK GRN/YEL
TWISTED
DK GRN
RED
--BLK/WHT
---
COLOR
6-PIN CONNECTOR
- OR -
BLK/WHT
RED
DK BLU
DK BLU/WHT
WHT/BLU
DK GRN/YEL TWISTED
DK GRN
-----
COLOR
9-PIN CONNECTOR
BLK/WHT
COLOR
N.O.
CONNECTOR DDC P/N: 23529496

COVER DDC P/N: 23529497
TERMINAL DDC P/N: 23507132
A
B
C
D
E
F
G
H
J
CAVITY
CONNECTOR DDC P/N: 23513052

COVER DDC P/N: 23513054
TERMINAL DDC P/N: 23513053
A
B
C
D
E
F
CAVITY
DIGITAL INPUT*
WIRE NO.
953
440
925
926
927
900
901
-----
WIRE NO.
900
901
440
--953
---
DIAGNOSITC REQUEST
AND STOP ENGINE
OVERRIDE SWITCH
BATTERY GROUND
+12/24V
J1939 DATA LINK (+)
J1939 DATA LINK (-)
J1939 SHIELD
DATA LINK (+)
DATA LINK (-)
PLUG P/N: 23507136
PLUG P/N: 23507136
LABEL
DATA LINK (+)

DATA LINK (-)
+ 12/24 VDC
PLUG P/N: 23507136
BATTERY GROUND
PLUG P/N: 23507136
LABEL
NOTE:
FUSE MUST BE PLACED BETWEEN
MATING CONNECTOR AND BATTERY
WIRE NO.
+ 12/24 VDC
WIRE NO COLOR
439
PNK
MUST PROVIDE IGNITION POWER

IN RUN AND CRANK MODES.
DO NOT SOURCE ANY
ACCESSORY FROM CIRCUIT 439
SWITCHED
IGNITION
ORN
CONNECTOR
DDC P/N 12015378
TERMINAL
DDC P/N 12089188
440
DEDICATED 12/24 VDC BATTERY POWER

MUST BE SOURCED DIRECTLY
FROM BATTERY POST OR BUS BAR
953
GOVERNOR
BRN
- OR -
OI T-STAT
SET/COAST
SWITCH
DIGITAL INPUT*
LT BLU/ORN
557
OFF
OFF
416
910
905
953
439
452
976
RETURN
SIGNAL
WHT/BLU
PNK
TAN
TAN/WHT
439
801
800
C
B
A
DK BLU/WHT
DK BLU
WIRE
COLOR
CONNECTOR
(10-PIN)
APEX P/N: 54201016
TERMINAL
APEX P/N:
LSP-1811-58AU
J 1922 (+) DATA LINK
J 1922 (-) DATA LINK
IGNITION (OPTIONAL)
CAN_SHLD/J 1939 SHIELD
42893
CAN_L/J 1939 (-) CONTROL DATA LINK
CAN_H/J 1939 (+) CONTROL DATA LINK
LABEL
DIGITAL OUTPUT W-3
DIGITAL OUTPUT Y-3

DIGITAL OUTPUT X-3
SENSOR SUPPLY
OI STARTER
TURBO COMP INLET
SENSOR RETURN
RELATIVE HUMIDITY
GND (VPOD GND)

IGN (VPOD POWER)
927
926
925
10
8
9
4
5
6
2
3
WIRE
NO.
YEL
563
COMMUNICATION
CONNECTOR
CAVITY
RED
TAN/BLK
565
564
BLK
PNK
BLK
WHT
GRA
ORN
YEL
WIRE NO COLOR
ON
ON
ON
ON
ON
VEHICLE SPEED SENSOR
CLUTCH
SWITCH
OFF
OFF
OFF
GN
OEM CONNECTION TO ESH
LT
BLK/WHT
556
953
DIGITAL INPUT*
BRAKE
SWITCH
RESUME/ACCE
SWITCH
DIGITAL INPUT*
DIGITAL INPUT*
CRUISE
ENABLE
SWITCH
DIGITAL INPUT*
DASH PANEL
CRUISE CONTROL
DIGITAL OUTPUT*
+12/24
WIRE NO. COLOR
TO OI
STARTER
RELAY
1
2
COMMUNICATIONS CONNECTOR
P/N: 12066317
TERMINAL
P/N: 12103881
PLUG
P/N: 12034413
COMMUNICATION
HARNESS
TO VEHICLE
DIGITAL
OUTPUT
WIRING
RELATIVE HUMIDITY/
TCI
SENSOR
CONNECTOR
FC/APEX
P/N: 54200409
TERMINAL (GOLD)
P/N: JTP-1811-66AU
510
C
B
A
VARIABLE SPEED GOVERNOR

(POWER TAKE-OFF CONTROL)
916 RED/BLK
510
BRN
952
BLK
LIMITING SPEED GOVERNOR

(THROTTLE POSITION SENSOR)
WIRE NO COLOR
916 RED/BLK C
417 DK BLUE B
952
BLK
A
DDD-XX
XXXXX
WIRE NO. CAVITY

115
A
953
B
ORN
BLK/WHT
DK GREEN/YEL
DK GREEN
WHT
C-2
C-1
J-3
900
901
908
A
B
GRA/RED
GRA
BRN/RED
ORN
YEL/RED
YEL
ORN/BLK
BRN/WHT
LT BLUE/YEL
TAN
LT BLUE/BLK
LT BLUE/ORN
LT BLUE/BLK
YEL
H-1
H-2
G-1
J-2
J-1
F-1
G-2
F-2
G-3
A-2
E-2
E-3
K-2
D-3
523
524
528
531
541
542
543
544
545
555
556
557
583
749
COOLANT LEVEL SENSOR
+12 V FROM BATTERY

BATTERY GROUND
ORN
DK BLUE
PPL/WHT
PNK
LT GRN
LT BLU
GRA
PPL
BRN
COLOR
H-3
D-2
B-1
B-3
E-1
F-3
K-1
B-2
D-1
CAVITY
115
417
419
439
451
499
505
509
510
WIRE NO
IGNITION CONNECTOR
COOLANT LEVEL
LIMITING SPEED GOVERNOR
CHECK ENGINE LIGHT
IGNITION
DIGITAL INPUT E-1
DIGITAL OUTPUT F-3
TACHOMETER DRIVE
STOP ENGINE LIGHT
OI THERMOSTAT OR PTO OR
EXHAUST BACK PRESSURE (COACH ONLY)
DIGITAL INPUT H-1
DIGITAL INPUT H-2
DIGITAL INPUT G-1
DIGITAL INPUT J-2
DIGITAL INPUT J-1
DIGITAL INPUT F-1
DIGITAL INPUT G-2
DIGITAL INPUT F-2
DIGITAL INPUT G-3
DIGITAL OUTPUT A-2
VEHICLE SPEED (+)
VEHICLE SPEED (-)
DIGITAL INPUT K-2
ESS TRANS OR
FIRE TRUCK PUMP PRESSURE OR
EXHAUST TEMP
DATA LINK (+)
DATA LINK (-)
PWM FAN OR OI ALARM OR
PWM TRANSMISSION
SENSOR SUPPLY (5VDC)
SENSOR RETURN
DIGITAL INPUT K-3
DIGITAL OUTPUT A-1
LABEL
OEM RESPONSIBILITY
B A
SERIES 60 DDEC IV MY2003 EGR

VEHICLE INTERFACE HARNESS
Appendix
Detroit Diesel
DDEC IV Vehicle Interface Harness
V-30
V-31
V-32
V-33
V-34
V-35
V-36
V-37
V-38
V-39
V-40
V-41
V-42
V-43
V-44
V-45
V-46
V-47
V-48
V-49
V-50
V-51
V-52
V-53
V-54
V-55
V-56
V-57
V-58
V-59
V-60
V-61
V-62
V-63
V-64
V-65
V-66
V-67
V-68
V-1
V-2
V-3
V-4
V-5
V-6
V-7
V-8
V-9
V-10
V-11
V-12
V-13
V-14
V-15
V-16
V-17
V-18
V-19
V-20
V-21
V-22
V-23
V-24
V-25
V-26
V-27
V-28
V-29
CAVITY
All information subject to change without notice. (Rev. 6/05)

7SA821 0506 Copyright 2005 DETROIT DIESEL CORPORATION
AMBER WARNING LAMP

RED STOP LAMP
SERVICE BRAKE RELEASED
FAN CONTROL #1
DIGITAL OUTPUT
DIGITAL OUTPUT
VEHICLE PWR SHUTDOWN
RESUME/ACCEL
CRUISE ENABLE
CLUTCH RELEASED
SENSOR SUPPLY #1
SENSOR SUPPLY #2
THROTTLE POSITION
VSG
IGNITION
IDLE VALIDATION
VEHICLE SPEED SENSOR (+)
VEHICLE SPEED SENSOR (-)
NO CONNECTION
NO CONNECTION
NO CONNECTION
AIR FILTER RESTRICTION
EXHAUST TEMPERATURE
SEO/DIAG REQUEST
A/C STATUS
ANALOG INPUT - 1.5k PULLUP
TURBO COMPRESSOR IN TEMP
NO CONNECTION
EXHAUST BACK PRESSURE OR
FIRE TRUCK PUMP PRESSURE
NO CONNECTION
TACHOMETER
FREQUENCY - SPARE
FREQUENCY - SPARE
NO CONNECTION
NO CONNECTION
NO CONNECTION
ADD COOLANT LEVEL
COOLANT LEVEL - SHUTDOWN
ENGINE BRAKE LOW
OI ALARM
AUX SHUTDOWN #1
OI THERMOSTAT
J 1939 DL (+)
J 1939 DL SHIELD
NO CONNECTION
PWM OUTPUT
SET/COAST
ANALOG INPUT - 1.5k PULLUP
FAN CONTROL OVERRIDE
PARK BRAKE
ENG BRAKE MED
PWM OUTPUT
ETHER START
OI STARTER
OI ACTIVE LAMP
J 1587 +
J 1587J 1939 DL (-)
SENSOR RETURN #2
SENSOR RETURN #1
+12V / +24V
+12V / +24V
BATTERY GROUND
BATTERY GROUND
+12V / +24V
+12V / +24V
BATTERY GROUND
BATTERY GROUND
68-WAY CONNECTOR
DDC P/N: 23528252
14 AWG TERMINAL
DDC P/N: 23528272
68
65
45
60
41
56
40
55
31
46
64
61
BATTERY (+)
V-62
V-65
SWITCHED
IGNITION
SHROUD SIDE
OF CONNECTOR
TCI
V-27
SENSOR RETURN
V-38
V-60
SENSOR RETURN #1
SENSOR RETURN #1
SENSOR SUPPLY #1
PUMP PRESSURE
V-60
V-60
V-11
V-29
SENSOR SUPPLY #1
SENSOR RETURN #1
V-11
V-60
EXHAUST TEMPERATURE
EXHAUST BACK PRESSURE
V-29
V-23
SENSOR RETURN #1
V-60
COACH APPLICATIONS ONLY
AIR FILTER RESTRICTION
V-22
V-60
SENSOR SUPPLY #1
SENSOR RETURN
V-37
V-11
LABEL
ADD COOLANT LEVEL
CAVITY
MAINTENANCE ALERT SYSTEM ONLY
LABEL
COOLANT LEVEL
CAVITY
ENGINE COOLANT LEVEL SENSOR - SHUTDOWN
SENSOR RETURN #2
LABEL
CAVITY
V-59
30 AMP
IGNITION
FUSE
BATTERY (-)
BATTERY (+)
EXHAUST
TEMPERATURE
EXHAUST
BACK
PRESSURE
FIRE TRUCK
PUMP
PRESSURE
AIR
FILTER
RESTRICTION
ADD
COOLANT
LEVEL
COOLANT LEVEL
SENSOR
SHUTDOWN
TURBO
COMPRESSOR
IN TEMP
MUST PROVIDE IGNITION POWER

IN RUN AND CRANK MODES.
DO NOT SOURCE ANY NON-DDEC
ACCESSORY FROM IGN CIRCUIT (V-15)
V-15
BATTERY (-)
BATTERY (-)
V-68
BATTERY (-)
V-67
BATTERY (-)
V-64
V-63
BATTERY (+)
BATTERY (+)
V-61
V-66
LABEL
BATTERY (+)
CAVITY
POWER WIRING
TURBO COMPRESSOR IN TEMP
18 AWG TERMINAL
DDC P/N: 23528271
30
15
26
11
10
25
16
SENSOR RETURN #1
SENSOR SUPPLY #1*
INPUT
SENSOR RETURN #1
SENSOR SUPPLY #1*
INPUT
PWM OUTPUT
PWM OUTPUT
LOW SIDE DIGITAL OUTPUT
LOW SIDE DIGITAL OUTPUT
LABEL
CAVITY
TACH OUTPUT
AWL
RSL
LABEL
SENSOR RETURN
ENG. BRAKE MED
ENG. BRAKE LOW
AMBER WARNING LAMP
RED STOP LAMP
V-60
V-14
V-11
V-59
V-16
V-60
V-13
V-11
CAVITY
DIAG REQ/SEO
SENSOR RETURN
A/C STATUS
FAN CONTROL #1
SENSOR RETURN
FAN CTRL OVERRIDE
V-7
V-59
V-50
IGN
IGN
SENSOR RETURN #1
VSG
SENSOR SUPPLY #1
SENSOR RETURN #2
IDLE VALIDATION
SENSOR RETURN #1
ALSG
SENSOR SUPPLY #1
LABEL
IGN
+12/24V
LABEL
OI ALARM
OI STARTER
OI ACTIVE LAMP
V-43
V-58
V-44
V-56
V-57
-
CAVITY
SET/COAST
SWITCH
TERMINAL
DEUTSCH P/N: 0460-202-16141
DDC P/N: 23507132
A
B
C
D
E
F
G
H
J
ON
SIGNAL
+12/24V
+12/24V
CONNECTOR COVER
DEUTSCH P/N: HDC16-9
DDC P/N: 23529497
CAVITY PLUG
DEUTSCH P/N: 114017
DDC P/N: 23507136
GND
+12/24 V
J 1939 DATA LINK (+)
J 1939 DATA LINK (-)
J 1939 SHIELD
J 1587 DATA LINK (+)
J 1587 DATA LINK (-)
PLUG
PLUG
LABEL
+12/24V
RETURN
40106
OFF
ON
OFF
VEHICLE SPEED SENSOR
TO PIN D
OF
THERMOSTAT
CONNECTOR
DDC CONNECTOR
OFF
ON
OFF
ON
ON
OFF
SENSOR RETURN #2
CLUTCH
SWITCH
SERVICE BRAKE
SWITCH
OI THERMOSTAT
CONNECTOR
DEUTSCH P/N: HD10-9-1939P
DDC P/N: 23529496
V-42
CRUISE
ENABLE
SWITCH
RESUME/ACCEL
SWITCH
(REFER TO OPTIMIZED IDLE FOR RELAY REQUIREMENTS)
V-40
V-54
V-55
CAVITY
V-18
V-17
V-59
V-10
V-3
V-47
V-8
V-9
OPTIMIZED IDLE (OPTIONAL)
VARIABLE
SPEED
GOVERNOR
(OPTIONAL)
IDLE
VALIDATION
(REQUIRED)
AUTOMOTIVE
LIMITING
SPEED
GOVERNOR
DASH PANEL
CRUISE CONTROL
DIGITAL OUTPUT
+12/24V
CAVITY
DDEC V
VEHICLE INTERFACE HARNESS
VEHICLE POWER SHUTDOWN
SENSOR RETURN
PARK BRAKE
GOVERNOR
THROTTLE PEDAL
DIAGNOSTIC REQ/
SEO SWITCH
PARKING BRAKE & VEHICLE POWER SHUTDOWN
V-4
V-59
V-49
V-25
FAN CONTROL - SINGLE SPEED FAN
V-59
V-24
DIAGNOSTIC REQUEST / STOP ENGINE OVERRIDE
V-59
V-51
V-39
ENGINE BRAKE SWITCHES
V-31
V-01
V-02
INPUT WITH
1.5k PULL-UP
INPUT WITH
1.5k PULL-UP
INSTRUMENT PANEL
* NOT USED FOR DIGITAL INPUTS

RESISTORS ARE INTERNAL TO ECU
V-60
V-11
V-26
V-60
V-11
V-48
V-46
V-52
V-6
V-5
CAVITY
SPARE DIGITAL & PWM OUTPUTS/INPUTS
Appendix
LABEL
Appendix
DDEC V Vehicle Interface Harness
32
Appendix
Torque Specifications
Part
Torque
Flywheel capscrews
Follow engine manufacturers specifications
Transmission-to-Engine capscrews
7/16-14 *
37 - 50 lbs. ft. [50 - 68 Nm]
3/8-16 *
25 - 32 lbs. ft. [34 - 43 Nm]
M10 x 1-3/8 *
26 - 35 lbs. ft. [35 - 47 Nm]
M10 x 1-3/4 *
26 - 35 lbs. ft. [35 - 47 Nm]
Output yoke nut
450 - 500 lbs. ft. [610 - 678 Nm]
PTO mounting capscrews:

6-bolt opening *
20 - 25 lbs. ft. [27 - 34 Nm]
8-bolt opening *
50 - 65 lbs. ft. [68 - 88 Nm]
Reverse switch (9/16-18)
20 - 25 lbs. ft. [27 - 34 Nm]
Neutral switch/cap (3/4-16)
20 - 25 lbs. ft. [27 - 34 Nm]
Speedometer electronic sensor (3/4-16)
10 - 15 lbs. ft. [14 - 20 Nm]
Lubricant fill plug (1-NPT)
60 - 75 lbs. ft. [81 - 101 Nm]
Lubricant drain plug (3/4-NPT)
45 - 55 lbs. ft. [61 - 75 Nm]
Lifting bracket capscrew (3/8-16)
35 - 45 lbs. ft. [47 - 61 Nm]
Rear bearing cover capscrew (3/8-16)
35 - 45 lbs. ft. [47 - 61 Nm]
Transmission nodal mount capscrews (3/4-10)
180 - 190 lbs. ft. [244 - 258 Nm]
Transmission rear support stud nuts (5/8-18)
170 - 185 lbs. ft. [230 - 250 Nm]
Range Air Valve Mounting Screw (#10-24)
21 - 27 lbs. in. [2 - 3 Nm]
* Thread adhesive sealant required.
33
Appendix
Suggested Tools
O.E. Tool & Equipment Group/Kent-Moore SPX Corporation 1-800-520-2584
Kent-Moore Part no.
Description
5505027
Volt/Ohm Meter (Standard commercially available VOM)
O.E. Tool & Equipment Group/Kent-Moore SPX Corporation 1-800-328-6657

Kent-Moore Part no.
Description
J-43318
Eaton Test Adapter Kit

MD-100
Eaton Service Parts 1-800- 826-HELP (4357)

Part No.
Description
MD-200
Engine Tools
Contact your local engine representative for the latest tools specifications.
Related Publications
Troubleshooting Guide
TRTS-0070
Service Manuals
TRSM-0550 - RTLO 10-speed Models

TRSM-0670 - RTLO 13-speed, 18-speed, and Convertible
Models
Illustrated Parts Lists
See model specific listing
Driver Instructions
TRDR-0550 - RTLO 10-speed Models

TRDR-3349 - Convertible Models
Lubrication Requirements
TCMT-0020 - Roadranger Products Approved Lubricants
Appendix
TCMT-0021 - Roadranger Products Lubrication Manual

For additional information call the Roadranger Call Center at 1-800-826-HELP (4357).
34
Appendix
Application Forms
Eaton Fuller
Form FUL-169
Transmissions
Approved Applications For Fuller Twin Countershaft Mechanical and Top-2 Transmissions
Written Approval Required For All Applications Not Meeting the Requirements of This Form - Use Form FUL170 (Request for Application Approval).
All approvals are based on the following conditions:
Lubricants must meet the requirements published in Eaton TCMT-0021.
Driveline speed not to exceed 3000 RPM except RT-6609 -4000 RPM.
Angular acceleration of driveline is not to exceed 300 rad/s 2 .
High Angle lubrication kit required when installation angle plus operating grade angle exceeds 12 degrees (20%).
Vehicle must have sufficient overall reduction to insure Startability (See Startability Attachment FUL-171).
PTO torque limit - Maximum combined PTO output torque is not to exceed 500 lbs-ft for Lightning, FR/FRO and Convertible series transmissions.
All other transmissions are limited to a maximum of 350 lbs-ft with the standard input shaft bearing (P/N 82504). IF the input shaft bearing is
upgraded (P/N 4301417), the PTO output torque is not to exceed 500 lbs-ft. The RT-6609 is limited to 300 lbs-ft.
The maximum allowable torque at the transmission input shaft, due to engine retarding systems and engine friction, must be less than 110% of
maximum transmission torque rating.
Transmission input torque spikes due to drive train resonance, must be less than 300 lbs-ft above the nominal transmission input torque
rating for engine speeds above 1000 RPM and vehicle road spee d above 20 MPH.
Vehicle configurations that exceed the 3000 RPM driveline speed can be blanket approved IF the engine is electronically programmed to limit
the vehicle speed that produces a driveline speed of 3000 RPM or less in top (overdrive) gear.
3
Max
Gross
H.P.
250
Max. Peak
Torque
lbs-ft
RT-6609-A
74,000 Lbs.
860
RT-8608-L
RT-8908-LL
RT-8709-B
FR-9210B
10XXX
80,000 Lbs.
950
1050
1150
400
450
500
600
700
NOTE 2
GCW limit
for Blanket
Approval
660
300
370
3, 4
Transmission
Series
1250
1350
1400
1450
1550
1650
1750
1850
2050
2250
All Other 11XXX

RTO-11909-XLL
12XXX
13XXX
T-14607
All Other 14XXX
15XXX
16XXX
17XXX
18XXX
RTLO-20913/18
RTLO-22918
2-A-92
AT-1202
Maximum
Driveline
Torque, "A"
9,700
NOTE 1 A calculation
A1 or A2 must be less than A
A1 = Peak Engine Torque x
Lowest Gear Ratio
A2 =
12,500
17,500
Where:
672 x W
M x AR
W =Weight on drive wheels Lbs.
M =Tire revolution per mile
AR =Axle ratio
NOTE 2 "A" calculation for Auxiliaries

90,000 Lbs.
15,500
140,000 Lbs.
17,500
150,000 Lbs.
9,700
17,500
NOTE 3 Transmission Oil Coolers are:

Recommended With engines of 350 H.P. and above.
Required
With engines 400 H.P. and above, and
GCW s over 90,000 lbs.
With engines 400 H.P. and above and
1400 lbs-ft or greater torque
With engines 450 H.P. and above
With engines 1500 lbs-ft and above
In all cases, cooler must have sufficient capacity to maintain
oil temperatures below 250F at worst case operating
conditions.
Additional Application Requirements for Approval of RTLOC-1X909A-T2:

Application must be for On-Highway 5 use only.
For engines certified by Eaton for use with Top 2 transmissions, see Form FUL-200T.
Vehicle must have a minimum of 0.3% gradeability at cruise speed and 1% gradeability at peak torque. Calculations are to be made at
maximum rated conditions.
Vehicles using Detroit Diesel S60 engines must have rear axle ratio higher than 3.70 and tires with 492 revs/mile or greater.
Vehicles using Caterpillar C11, C13 or C15 engines must have a rear axle ratio higher than 3.55 and tires with 492 revs/mile or greater.
Any Progressive Shift engine programming must allow automatic up-shift points to be reached minimum 1500 RPM.
Vehicle must have a 12-volt electrical system.
Vehicle air system must include an air dryer.
4
Blanket GCW limit is just a limit for Blanket approved applications. Applications that exceed this limit need to be submitted to Eaton Corporation for approval.
On-Highway is defined as limited access and general highways. Grades less than 8%, well maintained, concrete or asphalt surface, no more than 10% offhighway operation. Maintained gravel, crushed rock, hard packed dirt or similar road surfaces are acceptable when grades are less than 3%.
11/03
35
Appendix
Eaton Fuller
Application Approval Form FUL-170 Rev. 01/04
Transmissions
Approval I.D. No.:
Chassis #(s):
No. of Vehicles:
Projected Build Date:
OEM / Plant Location:
Customer/Fleet:
APPROVAL REQUEST FOR:
Dealer Information
Dealership Name:
Dealer Address:
Contact:
Telephone:
FAX:
Transmission Model
ENGINE INFORMATION:
Make:
Rated Horsepower
Governed Speed:
Oil Cooler:
Model:
at
RPM
Peak Torque
RPM
Top Speed Limit Setting
DRIVELINE INFORMATION:
Rear Axle
Make:
Drive Tires Make:
Retarder
Make:
Clutch
Make:
Trans Case Make:
/Aux. Trans
CHASSIS INFORMATION
Model:
Max Weight on Drive Wheels
Model:
Model:
Model:
Model:
Model:
YES
Displacement:
Liters
Lbs-ft at
RPM
MPH Cruise Speed
MPH
Ratios:
Size:
Type:
/
or Revs/Mile
HP
Ratios:
Drive Configuration (6x4, 4x2)

Lbs Max GVW
Vehicle Voltage (12 or 24v)

Lbs Max GCW
VOCATIONAL AND BODY SPECIFIC INFORMATION:

Vocation (Line Haul, Dump, Refuse, Mixer, etc)
Body Type
Trailer Type
Area of Operation:
Country(s)
State / Province/Region
Road Usage: Highway
% Secondary/City
% Off-Highway
Maximum Grade on Which Vehicle will be Required to Operate
%
PHONE:
12
V
Lbs
# Trailers
% Off-Road
TRANSMISSION FEATURE / OPTION REQUIREMENTS: (CHECK BOX OF APPROPRIATE CONFIGURATION)

6 Bolt Engine
Split-Shaft
Countershaft: 6 Bolt
8 Bolt
PTO
Usage: None
PTO Model:
PTO Driven Equipment:
PERSON SUBMITTING REQUEST
NO
Aux
FAX:
FIRM NAME & ADDRESS:

THIS APPLICATION IS:
ADDITIONAL NOTES / REQUIREMENTS:
SIGNED:
1.
3.
This Application Approval Form (FUL-170) is intended for use as an approval for warranty
ONLY. An approval indicates that the given configuration meets the minimum requirements of
the specified product; it does not indicate approval to ship the product.
All Eaton warranty guidelines apply for coverage and specific labor repair times. Reference
Eaton publications TCWY-0600 and TCWY-0900.
Refer to form FUL-169 ( ) for Blanket Application Requirements.
DATE:
Eaton Corporation TOA
P.O. Box 4013
Kalamazoo, MI 49003
Phone: (269) 342-3000
Fax: (269) 342-3574
TransApplications@Eaton.com
Appendix
2.
APPLICATION ENGINEER:
36
Copyright Eaton and Dana Corporation,

2007. EATON AND DANA CORPORA TION
hereby grants its customer s, vendor s, or
distributor s 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.
Fo r specing 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 ro ad. O r visit our w eb sit e at www .roadr ang er.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
Eaton Corporation Truc k Components Operations P. O. Bo x 4013 K alamaz oo, MI 490 03 U.S.A. www .roadranger .com

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Fuller Heavy Duty Transmissions

More time on the road

Warnings and Cautions

Warnings and Cautions

This symbol is used throughout this

Failure to follow indicated

Failure to follow indicated

Highly recommended procedures for

Always use genuine Eaton replacement parts.

Warnings and Cautions

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

How to Use This Manual

Electrical Requirements - All wires are to be a minimum of 16 gauge GXL.

9- / 13-speed Valve Location

18-speed Valve Location

Includes all Roadranger Approved comparable synthetic lubricant.

Proper Lubricant Level

28 pints (13.2 liters)

26 pints (12.3 liters)

28 pints (13.2 liters)

Improper Oil Level

Proper Oil Level

Proper Lubrication Levels as Related to Transmission Installation Angles

Percent Grade Converted to Degrees

Limitations for Proper Lubrications

Transmission Mounting Angle

Air Supply Requirements

Minimum air requirement for the transmission is 65 PSI.

A minimum of 1/4 diameter air supply line is required.

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

Do not tie wrap air line

9-speed Pneumatic Diagrams

5/32" or 1/8" air line

5/32" air line

1/4" air hose

1/4" air hose

1/4" air hose

1/4" air hose

5/32" air line

10-speed Pneumatic Diagrams

13-speed Pneumatic Diagrams

18-speed Pneumatic Diagrams

Transmission Mounting Requirements

Output Yoke/Flange Installation

Mounting Transmission to Engine

Using Rear Supports

The OEM is responsible for nodal mount design.

Typical Rear Support Designs

Top 2 Valve Electrical Requirements

Mating connector description:

Wiring Diagram OEM Responsibility

End-of-Line Programming at the OEM

Programming at the Distributor Site

Top Gear Minus

Top Gear Minus

Top Gear Ratio

Caterpillar Schematic Diagram

Engine Ground Stud

Caterpillar Wiring Diagram

Detroit Diesel Programming

End-of-Line Programming at the OEM

Programming at the Distributor Site

DDEC III and IV