installation guide - roadranger
TRANSCRIPT
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
Dimensions shownare: mm [in]
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
Dimensions shownare: mm [in]
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
ElectricalSystemRequirements
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
ElectricalSystemRequirements
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
System Manager 32-Way Connector
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
FIREWALL CONNECTOR WIRE TABLE
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
Shift Lever 24-Way Connector
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
ElectricalSystemRequirements
Ignition Circuit Breaker Power Harness
1017-3-97
ECU CONNECTOR WIRE TABLESHIFT LEVER (24 PIN)WIRE DESCRIPTION PIN LOCATIONVIGN A1
FIREWALL CONNECTOR WIRE TABLE
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
Shift Lever 24-Way Connector
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
System Manager 24-Way Connector
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
FIREWALL CONNECTOR WIRE TABLE
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
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
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
ElectricalSystemRequirements
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)
(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
(FROM POWER CONNECT RELAY OUTPUT)
(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 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
ElectricalSystemRequirements
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
Shift Lever 24-Way Connector
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
System Manager 24-Way Connector
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
Shift Lever 24-Way Connector
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
System Manager 24-Way Connector
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
ElectricalSystemRequirements
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
ElectricalSystemRequirements
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
1.00 MeterMax Length
40.00 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
System Manager 32-Way Connector
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.
ElectricalSystemRequirements
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
ElectricalSystemRequirements
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
Packard 24-Way Connector12110088120896491204790012047901
Mating ConnectorTerminal Secondary Lock Secondary Lock
D HOLD LHR N
A B C
A B C
Packard 24-Way Connector12047946120896491204790012047901
Mating ConnectorTerminal Secondary Lock Secondary Lock
Packard 3-Way Connector120477821204758112047784
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
Packard 6-Way Connector120663171210388112034413
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
Dimmer Control Input
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
TransmissionInterfaceHarness
(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
Dimmer Control Input
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
TransmissionInterfaceHarness
(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.
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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.