trig 00701007 installation guide fuller heavy duty transmissions
DESCRIPTION
A reference guide for the installation of all Top 2 series transmissionsTRANSCRIPT
Fuller® Heavy Duty Transmissions
Installation GuideFuller Heavy Duty Transmissions
TRIG0070
October 2007
More time on the road ®
RTLO-11610B
RTLO-11610B-T2
RTLO-12610B
RTLO-12610B-T2
RTLO-12713A
RTLO-12913A
RTLO-13610B
RTLO-13610B-T2
RTLO-14610A
RTLO-14610B
RTLO-14610B-T2
RTLO-14613B
RTLO-14618A
RTLO-14713A
RTLO-14718B
RTLO-14913A
RTLO-14918B
RTLO-14918B-T2
RTLO-15610B
RTLO-15610B-T2
RTLO-16610B
RTLO-16610B-T2
RTLO-16618A
RTLO-16713A
RTLO-16713A-T2
RTLO-16718B
RTLO-16913A
RTLO-16913A-T2
RTLO-16918B
RTLO-16918B-T2
RTLO-17610B
RTLO-17610B-T2
RTLO-18610B
RTLO-18610B-T2
RTLO-18718B
RTLO-18718B-T2
RTLO-18913A
RTLO-18913A-T2
RTLO-18918B
RTLO-18918B-T2
RTLO-20913A
RTLO-20918B
RTLO-20918B-T2
RTLO-22918B
RTLOC-16909A-T2
RTLOF-11610B
RTLOF-11610B-T2
RTLOF-12610B
RTLOF-12610B-T2
RTLOF-12713A
RTLOF-12913A
RTLOF-13610B
RTLOF-13610B-T2
RTLOF-14610B
RTLOF-14610B-T2
RTLOF-14613B
RTLOF-14618A
RTLOF-14713A
RTLOF-14718B
RTLOF-14913A
RTLOF-14918B
RTLOF-14918B-T2
RTLOF-15610B
RTLOF-15610B-T2
RTLOF-16610B
RTLOF-16610B-T2
RTLOF-16618A
RTLOF-16713A
RTLOF-16713A-T2
RTLOF-16718B
RTLOF-16913A
RTLOF-16913A-T2
RTLOF-16918B
RTLOF-16918B-T2
RTLOF-17610B
RTLOF-17610B-T2
RTLOF-18610B
RTLOF-18718B
RTLOF-18913A
RTLOF-18913A-T2
RTLOF-18918B
RTLOF-18918B-T2
RTLOF-20913A
RTLOF-20918B
RTLOF-20918B-T2
RTLOF-22918B
RTLOFC-16909A-T2
Warnings and Cautions
Warnings and Cautions
The description and specifications contained in this service publication are current at the time of printing.
Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice.
Important Notice
Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used.
Always use genuine Eaton replacement parts.
Every effort has been made to ensure the accuracy of all information in this guide. However, Eaton makes no expressed or implied warranty or representation based on the enclosed information.
This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and/or component damage.
Departure from the instructions, choice of tools, materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator.
Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician.
Failure to follow indicated procedures may cause component damage or malfunction.
Highly recommended procedures forproper service of this unit.
Note: Additional service information not covered in the service procedures.
Tip: Helpful removal and installation procedures to aid in the service of this unit.
WARNING
CAUTION
IMPORTANT
Table of ContentsTable of Contents
Warnings and CautionsWarnings and Cautions ...............................................i
General InformationHow to Use This Manual ............................................1
Installation RequirementsRequirements .............................................................2Space Requirements ..................................................3
10-speed Valve Location ........................................39- / 13-speed Valve Location ..................................518-speed Valve Location ........................................6
Lubrication Requirements ..........................................8Air Supply Requirements ..........................................10
9-speed Pneumatic Diagrams ...............................1110-speed Pneumatic Diagrams .............................1213-speed Pneumatic Diagrams .............................1318-speed Pneumatic Diagrams .............................14
Transmission Mounting Requirements ....................15Mounting Transmission to Engine ........................16Using Rear Supports ............................................17Typical Rear Support Designs ...............................17
Electrical RequirementsTop 2 Valve Electrical Requirements ........................ 18Wiring Diagram OEM Responsibility ........................ 19
Caterpillar Programming ...................................... 19Detroit Diesel Programming ................................. 21
Line InspectionLine Inspection and Road Test Instructions ............. 26Line Inspection Form ............................................... 27Troubleshooting ....................................................... 28
AppendixWiring Diagrams ...................................................... 29
Caterpillar ............................................................. 29Detroit Diesel ........................................................ 31
Torque Specifications .............................................. 33Suggested Tools ...................................................... 34Related Publications ................................................ 34Application Forms .................................................... 35
1
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 out-lined in Form FUL-169. Applications outside of these requirements must be approved by Eaton Engineering using Form FUL-170.
All information contained in this manual was accurate at the time of printing. With each new application, engine manufacturers should be contacted to make sure desired engines are compatible with the Top 2 system.
2
Installation RequirementsInstallation
Requirements
Requirements
All Top 2 transmission systems installed at OEM facilities must meet the requirements for standard manual Eaton Fuller Transmissions outlined in Form FUL-169 and be approved using the Eaton Automated Transmission Application Approval Form FUL-170. Both forms can be found in the Appendix.
1. Air Dryer Requirements - A high quality commercially available vehicle air dryer is required to be used in conjunction with Top 2 systems.
2. Clutch Requirements - Spring dampened clutches are required for all applications.
3. Electrical Requirements - All wires are to be a minimum of 16 gauge GXL.
4. Integral Coolers - Reference Form FUL-169 Note 2 for transmission cooler requirements.
5. Line Inspection - All Eaton Top 2 transmission systems installed at OEM plants must pass the requirements outlined in the “Line Inspection Form” prior to shipment.
6. Lubrication Requirements - Transmission oil should meet specifications as outlined in TCMT-0020 (Roadranger Prod-ucts Approved Lubricants) and TCMT-0021 (Roadranger Products Lubrication Manual).
7. Power Connections - All ECMs will have redundant power and ground pins. If no redundancy is available, a relay con-nection similar to the one on page 29.
8. Valve Spatial Requirements - The Top 2 solenoid valve requires a minimum of 2” clearance from any high temperature devices (i.e. exhaust crossover pipes).
Installation Requirements
Space Requirements
10-speed Valve LocationNote: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.
3
Installation RequirementsInstallation
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)
4
Installation Requirements
9- / 13-speed Valve Location
Note: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.
5
Installation RequirementsInstallation
Requirements
18-speed Valve LocationNote: Refer to “Transmission Mounting Requirements” for Valve Spatial Requirements.
MODEL LENGTH “A” LENGTH “B” LENGTH “C”
12713 815.1 (32.09) 200.4 (7.89) 43.9 (1.73)
14713 823.2 (32.41) 208.5 (8.21) 51.8 (2.04
16713 823.2 (32.41) 208.5 (8.21) 46.5 (1.83)
12913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
14913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
18913 840.7 (33.09) 226.1 (8.9) 69.6 (2.74)
6
Installation Requirements
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)
7
Installation RequirementsInstallation
Requirements
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.
Includes all Roadranger Approved comparable synthetic lubricant.
Proper Lubricant Level
Note: Failure to adhere to Eaton Installation Requirements may effect transmission performance and /or warranty coverage.
Note: The quantity for proper fill level will vary from model to model.
Make sure lubricant is level with fill hole opening. Because you can reach lubricant with your finger does not mean lubricant is at the proper level. (On heavy duty transmissions, one inch of lubricant level equals about 8 pints of oil).
Recommended Lubricant
Type Grade (SAE) Temperature
Roadranger CD50 Transmission Fluid
50 ALL
Transmission Capacity
9-Speed 28 pints (13.2 liters)
10-Speed 26 pints (12.3 liters)
13/18-Speed 28 pints (13.2 liters)
Improper Oil Level
Hole
Proper Oil Level
Hole
8
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 transmis-sion mounting angle in the chassis plus the percent of upgrade (expressed in degrees).
For example: If you have a 4 degree transmission mounting angle, then 8 degrees (or 14 percent of grade) is equal to the limit of 12 degrees. If you have a 0 degree mounting angle, the transmission can be operated on a 12 degree (21 percent) grade.
Note: The chart shows the effect a lubricant level 1/2” below normal can have on safe operating angles. Operating the vehicle 1/2” low on lubricant reduces the safe degree of grade by approximately 3 degrees (5.5 percent).
Note: For transmissions with cooler’s 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.
12o
11o 20'
10o 13'
9o 16'
8o
6o 51'
5o 48'
4o 35'
3o 26'
2o 18'
1o 8'
0o
0o 1o 2o 3o 4o 5o 6o 7o
22
20
18
16
14
12
10
8
6
4
2
0
Transmission Mounting Angle
Dotted line showing "2 Quarts Low" is for reference only.Not recommended.
Proper Lubrication Levels are Essential!
Perc
ent G
rade
Con
verte
d to
Deg
rees
Lim
itatio
ns fo
r Pro
per L
ubric
atio
nsPe
rcen
t of G
rade
TRANSMISSION OIL LEVEL 1/2" BELOW FILLER HOLE
2 QUARTS LOW
TRANSMISSION OIL LEVEL TO BOTTOM OF FILLER HOLE
9
Installation RequirementsInstallation
Requirements
Air Supply Requirements
1. It is required to use a high quality commercially available air dryer in the air supply line before the transmission.
2. Minimum air requirement for the transmission is 65 PSI.
3. A minimum of 1/4” diameter air supply line is required.
4. The transmission air supply is required to be routed from the air tank, which supplies air to either the front or rear vehi-cle service brakes, with a gauge indicator in the cab.
5. Transmission airlines should not be routed or attached at the bottom air tank fittings to avoid any chances of introduc-ing moisture into the airline.
6. Care should be used when routing the air supply to avoid kinks and close contact to heat sources.
7. The transmission air supply must be connected to the air filter/regulator mounted on the range cylinder cover.
Note: The air filter/regulator must not be removed during installation.
8. Air additives such, as alcohol devices should not be permitted to enter the transmission air supply. Additives could cause damage to air system components, which could lead to degraded transmission performance.
SERVICE TANK
AirDrying
Compressor
Do not tie wrap air line to wire harness on transmission
CAUTION
10
Installation Requirements
9-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
Roadranger valve
HI Range InactiveLO Range Pressured
HI Range PressuredLO Range Inactive
5/32" or 1/8" air line
1/4" air hose
1/4" air hose
HI Range InactiveLO Range Pressured
RangeCylinder
1/4" air hose
Constant regulatedair (55-65 PSI)
Air filter/regulator
Constant regulatedair (55-65 PSI)
1/4" air hoseSplitter Cylinder
5/32" air line
Lock HighExcept DuringTop 2 Function
Top 2 SolenoidValve
HI Split PressuredLO Split Inactive
5/32" air line
5/32" air line
Constant regulatedair (55-65 PSI)
5/32" or 1/8" air line
Slave Valve
H L
S PSL
P1P2
S
EXH
11
Installation RequirementsInstallation
Requirements
10-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
12
Installation Requirements
13-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
13
Installation RequirementsInstallation
Requirements
18-speed Pneumatic Diagrams
Note: Only solid lines are connected by the OEM. Dashed lines are already plumbed.
14
Installation Requirements
Transmission Mounting Requirements
Handling
Handle the transmission carefully to avoid damage to the transmission components and surrounding vehicle components.
1. Use a hoist or transmission jack that permits precise control of 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 N•m], (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 N•m] (3/8-16).
Output Yoke/Flange Installation
Note: The output yoke/flange is supplied with the transmission. If the output Yoke/flange must be replaced, the following proce-dure should be followed. (For detailed instructions, refer to the proper transmission model service manual.)
Select the proper output yoke per specified application, remove plastic cover, and inspect the slinger (gold anodized ring) and seal surface for damage or contamination. Do not use the yoke/flange if the slinger or seal surface is damaged such as dents, nicks, or scratches.
1. Prior to installation, remove all contamination such as styrofoam particles, dust, dirt, or rust in the machined surface of the yoke/flange.
2. Place the yoke/flange over the transmission output shaft end and rotate it to line up the splines. Take care not to bump any machined surface of the yoke/flange against the output shaft. Push the yoke all the way onto the output shaft and onto the seal with one continuous motion.
3. Thread the tail shaft nut onto the tailshaft until nylon insert is engaged on the tailshaft thread. Secure yoke/flange and tighten the tailshaft nut to 450-500 lbs-ft. [610-678 N•m].
15
Installation RequirementsInstallation
Requirements
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.
1. Use a two point lift chain or transmission jack with a minimum capacity of 1500 lbs.
2. Inspect the engine to transmission mating surfaces for damage or debris prior to installation. Make sure engine fly-wheel housing face, transmission clutch housing face, input shaft, etc. are free of paint, debris, rust, and any type of damage before installation.
3. Input Shaft To Clutch Alignment: The transmission is shipped from Eaton with the transmission in gear. The transmis-sion must be in gear in order to rotate the input shaft by turning the output shaft/yoke.
4. Adjust the lift chain or transmission jack to obtain the same relative angle as the engine. The face of the engine flywheel housing and the face of the transmission clutch housing must be parallel during installation. If the transmission is prop-erly aligned and the clutch is installed properly, very little force is required to slide the input shaft through the clutch and into the pilot bearing.
5. If interference is encountered, move the transmission away from the engine to investigate the cause. The use of exces-sive force to overcome misalignment may cause damage to the transmission input shaft and the clutch.
6. Rotate the output shaft/yoke while sliding the input shaft into the clutch to line up the splines.
7. Once the transmission is seated against the engine flywheel housing, align the clutch housing bolt holes with the engine flywheel housing bolt holes and install all capscrews and tighten finger tight.
Note: The clutch housing must be flush against the engine flywheel housing before tightening any capscrews. Do not use the capscrews to seat housing.
8. Tighten four capscrews at 90° intervals around the clutch housing, then tighten the remaining transmission mounting capscrews using the recommended torque specifications.
Note: Do not tighten any mounting capscrews until all capscrews have been installed and finger tightened. Do not remove the transmission support chain or jack until all mounting bolts have been tightened.
16
Installation Requirements
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 N•m] of torque
Typical Rear Support Designs
17
18
Electrical RequirementsElectrical
Requirements
Top 2 Valve Electrical Requirements
Mating connector description:
Designation Description Part Number Quantity
Connector Body 12110293 1
J1 Cable Seal 12048086 3
Terminal 12048074 3
Secondary 12052845 1
Electrical Requirements
Wiring Diagram OEM Responsibility
Caterpillar ProgrammingNote: All information on this page is only for a Caterpillar engine.
End-of-Line Programming at the OEM
Caterpillar units will already be programmed with all known features. The features simply need to be enabled. The “VEPS” soft-ware allows the OEM to activate / deactivate features.
Programming at the Distributor Site
Contact your Caterpillar representative for programming instructions.
Service Tool ET (Electronic Technician) allows for the activation of the “Eaton Top 2” Transmission Style parameter.
Once the Eaton Top 2 is activated, gear ratios must be programmed as well. Each ratio must be programmed to three decimal places. Those ratios are as follows:
Note: “XX” appearing in the transmission model number refers to the “XX” x 100 = Nominal Torque Capacity. For example, RTLO-14610B-T2 has a nominal torque capacity of 14 x 100 or 1400 lbs. ft.
Multi-function Output #7 is programmed as the “Shift Solenoid” in the Output Selections Group.
Multi-function Output #6 is programmed as the “Lockout Solenoid” in the Output Selections Group.
Caterpillar recommends locking out all Eaton Top 2 related parameters after programming has been completed and proper oper-ation has been verified.
Note: After parameters have been locked out, Factory Passwords are required to edit.
Transmission Model Top Gear Minus Two Ratio
Top Gear Minus One Ratio
Top Gear Ratio
RTLO-XX610B-T2 1.352 1.000 0.741
RTL-XX710B-T2RTL-XX910B-T2
1.825 1.351 1.000
RTLO-XX713A-T2RTLO-XX913A-T2
1.000 0.856 0.730
RTLO-XX718B-T2RTLO-XX918B-T2
1.000 0.856 0.730
RTLOC-1X909A-T2 1.000 0.856 0.730
19
Electrical RequirementsElectrical
Requirements
Caterpillar Schematic Diagram
Caterpillar Wiring Diagram
Interconnection Table
From Top 2 Solenoid Valve
To Engine Control Module Connector (P1)
Description
A 19 Lockout
B none Engine Ground Stud
C 20 Shift
19
20
20
Electrical Requirements
Detroit Diesel ProgrammingNote: All information on this page is only for a Detroit Diesel engine.
End-of-Line Programming at the OEM
DDEC units will already be programmed with all known features. The features simply need to be enabled. The “VEPS” software allows the OEM to activate / deactivate features or configure individual ECM pins. VEPS can assign any ECM pin to a specific function, as long as the physical function of the pin is compatible. Usually this is automatic with VEPS software, but can be assigned manually as well. This method is used after order entry when the required features are known.
Programming at the Distributor Site
DDEC units are programmed with all features and are setup in a similar fashion to the End-of-Line Programming. The distributor programming station will download the latest software version from the DDC mainframe. The distributor will trace back the wires from the Top 2 solenoids and manually enter in the individual pin numbers as assigned to the “Top 2 Lock-Out Solenoid” and the “Top 2 Shift Solenoid” drivers which then activates the Top 2 feature.
For further information, contact your Detroit Diesel representative.
Programming Information:
Diagnostic tools can verify the configuration of the solenoids with functional identifiers that are noted below.
The “Lockout” solenoid is given a functional identifier of 31.
The “Shift” solenoid is given a functional identifier of 30.
While Eaton recommends the use of Auxiliary Output 5 (W-3) as “Lockout” and the use of Auxiliary Output 7 (Y-3) as “Shift”, any two of the above outputs can be used.
DDEC III and IV
Circuit Name SID Pin Connection
Auxiliary Output #1 26 F-3 OEM Vehicle Interface Connector
Auxiliary Output #2 40 A-2 OEM Vehicle Interface Connector
Auxiliary Output #5 53 W-3 Top 2 3-Way Connector
Auxiliary Output #6 54 X-3 Top 2 3-Way Connector
Auxiliary Output #7 55 Y-3 Top 2 3-Way Connector
Auxiliary Output #8 56 A-1 OEM Vehicle Interface Connector
DDEC V
Circuit Name SID Pin Connection
Digital Output 40 V-5 Top 2 3-Way Connector
Digital Output 53 V-6 Top 2 3-Way Connector
21
Electrical RequirementsElectrical
Requirements
DDEC III and IV Schematic Diagram
Select two of the available six Auxiliary Outputs for use as “Lockout” and “Shift”.
These two selected pins must be noted and used during the programming of the ECM.
22
Electrical Requirements
DDEC V Schematic Diagram
Dig Output (V-5)Dig Output (V-6)
23
Electrical RequirementsElectrical
Requirements
DDEC III, IV and V Wiring Diagram
Typical DDEC III and IV System Overview
ECM DDEC III & IV
Vehicle Interface Connector
Top 2 Valve
24
Electrical Requirements
Typical DDEC V System Overview
DDEC III and IV ECM Harness Connector
Pins available for selection through engine sensor pigtail harness: W-3, X-3, and Y-3.
Note: Any two of the six pins listed may be used for “Lockout” and “Shift”. After deciding which two pins will be used, refer to the End-of-Line Programming information based on your engine type, to complete the programming of the ECM.
DDEC V ECM Harness Connector
DDEC III and IV OEM Vehicle Interface Connector
Pins available for selection: A-1, A-2, and F-3.
ECM DDEC V
Top 2 Valve
5540
25
16110
41
45
30
566015
68
6164
2611
65 4631
25
Line InspectionLine Inspection
Line Inspection and Road Test Instructions
Refer to the Line Inspection Form while performing the following procedure:
1. Power Supply Checks:
• DDEC - Visually verify the power connections at the battery bus through a 10 amp circuit breaker or fuse.
• Caterpillar - Visually verify the ground connection between the solenoids and truck.
• Cummins - Visually verify the ground connection between the solenoids and truck.
2. Oil Fill:
• Verify the transmission has been filled with the correct amount of oil and type before starting engine. Failure to add sufficient oil could damage the transmission. Use Eaton Roadranger CD50 or equivalent as specified in TCMT-0021 the Roadranger Product Lubrication Manual on the www.Roadranger.com Literature Center.
3. End-of-line Programming
• See page 19, page 21, page 29, or page 31 depending on your engine type.
Dyno / Road Test
4. Verify correct clutch adjustment and correct pedal free travel per clutch manufacturer’s 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 driver’s 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 Form
Inspection Sheet
Oem
Chassis S/N
Trans Model # Trans S/N
Description Yes No Corrected
Pre-Start Checks1. Power Supply check:2. Oil Fill - Eaton® Roadranger®
DYNO/ROAD TEST CHECKS4. Correct clutch free travel and adjustment5. All forward and reverse gears obtained
(Including Automatic Shifting Gears)6. Verify no transmission oil leaks7. Verify Top 2 shift label
Drivers Instructions book in cab8. Oil type & brand affixed to vehicle9. Clear Fault Codes in Engine ECMComments
Final Inspection DateSignaturePlease send copy to: Eaton Corp. FAX #(269) 383-5520 ATTN: Automation Installations Groupor mail copy to : Eaton Corp, 13100 E. Michigan Ave., Galesburg, MI 49053 ATTN: Automation Installations Group
TOP 2Line Inspection
27
28
Line InspectionLine Inspection
Troubleshooting
Check for proper lube level.See Lubrication Requirements.
The Splitter Button does not work and the transmission does not make
automatic shifts in the "AUTO"position.
Functional?
NO
YESResume operation.
Check for proper air pressure.See Pneumatic Air Diagrams.
Check transmission power circuits.See Schematic Diagrams for fuse
and ground information.
The Splitter Button does not work,however, the transmission does
make shifts in the "AUTO" position.
When Shift Lever is in the "AUTO"position, the transmission does not make any automatic shifts. Manual
splitter shifts are normal.
The Splitter Button does not work and the transmission does not make
automatic shifts in the "AUTO"position.
The Splitter Button does not work,however, the transmission does
make shifts in the "AUTO" position.
When Shift Lever is in the "AUTO"position, the transmission does not make any automatic shifts. Manual
splitter shifts are normal.
Functional?NO YES
Resume operation.Call the Roadranger Call Centerat 1-800-826-HELP (4357).
Appendix
Wiring Diagrams
Caterpillar
C11, C13, C15, and C18 OEM Diagrams (2003)
C977-B
U E
716-G
YG
879-O
RC
983-W
HC
984-Y
L
CLU
TC
H P
ED
AL P
OS
ITIO
N S
WIT
CH
100m
A100m
A
INP
UT
#11 (
NO
TE
L)
INP
UT
#15 P
OS
ITIV
E
RE
TA
RD
ER
SO
LE
NO
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OW
/HI S
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+5V
EN
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NT
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(N
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/HI S
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CH
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UT
#15 N
EG
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VE
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LE
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PO
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IVE
(N
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E F
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EH
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NE
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TIV
E IN
PU
T #
8 (
NO
TE
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14 A
WG
GX
L14 A
WG
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L14 A
WG
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L
AC
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LE
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TO
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EN
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R/S
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CH
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OR
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MM
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8V
AC
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RA
TO
R P
ED
AL P
OS
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N
2263
23
2 49
54 41
24
E971-G
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834-P
U
62
64
61
0.3
A C
UR
RE
NT
LIM
IT
0.3
A C
UR
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NT
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1 2
40
51
55
NO
TE
C: "S
ING
LE
" W
IND
ING
MA
GN
ET
IC P
ICK
UP
SE
NS
OR
RE
CO
MM
EN
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D
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TE
B: F
OR
SP
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ME
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RS
OR
TA
CH
OM
ET
ER
S W
ITH
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ING
LE
SIG
NA
L IN
PU
T T
ER
MIN
AL, E
ITH
ER
ON
E O
F T
HE
TW
O S
IGN
AL O
UT
PU
T L
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S F
RO
M T
HE
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M C
AN
BE
US
ED
. LE
AV
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RE
MA
ININ
G L
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DIS
CO
NN
EC
TE
D,
D
O N
OT
CO
NN
EC
T T
O G
RO
UN
D
5 4 66
25
32
33
69
68
VE
HIC
LE
HA
RN
ES
S C
ON
NE
CT
OR
P2 J
2
H795-P
KC
985-B
UC
986-B
R
L994-Y
L659-P
KK
998-B
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880-P
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RG
881-B
UG
882-W
H
SE
RV
ICE
BR
AK
E P
ED
AL P
OS
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N S
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CH
INP
UT
#7 (
NO
TE
L)
45
C992-P
U
INP
UT
SE
NS
OR
CO
MM
ON
#1
INP
UT
#5 (
NO
TE
L)
INP
UT
#6 (
NO
TE
L)
18
47
6 46
L901-G
YG
842-G
YG
843-O
RG
844-P
K
C974-P
UC
973-G
NE
718-P
KE
991-G
YG
836-W
H
CR
UIS
E C
ON
TR
OL O
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FF
SW
ITC
HIN
PU
T #
3 (
NO
TE
L)
INP
UT
#4 (
NO
TE
L)
59
60
7
C975-W
HK
982-Y
LG
841-G
N
SE
TR
ES
UM
EIN
PU
T #
1 (
NO
TE
L)
INP
UT
#2 (
NO
TE
L)
35
44
56
58
C978-B
RC
979-O
RK
999-G
NK
980-P
K
P1 J
1
G835-O
RG
808-B
UG
809-G
N G
845-P
U
J1587 D
AT
A L
INK
NE
GA
TIV
EJ1587 D
AT
A L
INK
PO
SIT
IVE
J1939 D
AT
A L
INK
SH
IELD
(N
OT
E K
& N
OT
E M
)J1939 D
AT
A L
INK
NE
GA
TIV
E (
NO
TE
K &
NO
TE
M)
J1939 D
AT
A L
INK
PO
SIT
IVE
(N
OT
E K
& N
OT
E M
)
UN
SW
ITC
HE
D +
BA
TT
ER
Y (
NO
TE
D)
UN
SW
ITC
HE
D +
BA
TT
ER
Y (
NO
TE
D)
-BA
TT
ER
Y
INP
UT
#9
INP
UT
#10
INP
UT
SE
NS
OR
CO
MM
ON
#2
INP
UT
#14
52
53
65
67
27 26
3 17
E717-G
N
101-R
D 1
01-R
D
229-B
K
G933-Y
L
C453-Y
L
993-B
R
F713-O
R
9 8 42
34
50
1 14
48
TA
CH
OM
ET
ER
PO
SIT
IVE
TA
CH
OM
ET
ER
NE
GA
TIV
E38
39
57
450-Y
L 4
51-B
R
SP
EE
DO
ME
TE
R P
OS
ITIV
ES
PE
ED
OM
ET
ER
NE
GA
TIV
EO
UT
PU
T #
2O
UT
PU
T #
3O
UT
PU
T #
4
36
37
10
12
13
15
1628
29
30
31
70
+/-
5 V
OLT
S
CH
EC
K E
NG
INE
LA
MP
WA
RN
ING
LA
MP
OU
TP
UT
#1
OU
TP
UT
#9
IGN
ITIO
N K
EY
SW
ITC
HIN
PU
T #
12
INP
UT
#13
E793-B
UE
794-Y
LA
249-B
KK
990-G
NK
900-Y
L
SP
EE
DO
ME
TE
R
NO
TE
EN
OT
E H
NO
TE
B
AC
CE
LE
RA
TO
R P
ED
AL
PO
SIT
ION
SE
NS
OR
40m
A5m
A
BK
RD
WH
J403 P
403
AC
CE
LE
RA
TO
R P
ED
AL S
EN
SO
R/S
WIT
CH
SE
NS
OR
CO
MM
ON
+8 V
AC
CE
LE
RA
TO
R P
ED
AL P
OS
ITIO
N
B A C
H795-P
K
H795-P
K
A/C
HIG
H P
RE
SS
. S
WIT
CH
N/C
E971-G
N
450-Y
L
451-B
R
SIG
NA
L+
SIG
NA
L-
NO
TE
B
TA
CH
OM
ET
ER
NO
TE
EN
OT
E H
E793-B
UE
794-Y
L
10A
PA
SS
IVE
MA
GN
ET
ICV
EH
ICLE
SP
EE
DS
EN
SO
R
G808-B
UG
809-G
N
H795-P
K
H795-P
K
E7
17
-GN
E7
16
-GY
SE
T/R
ES
UM
E
NO
TE
J
NO
TE
DN
OT
E D
EN
GIN
EB
LO
CK
CO
MP
ON
EN
TS
WIT
HIN
TH
IS A
RE
A A
RE
CA
TE
RP
ILLA
R P
RO
VID
ED
CLU
TC
H P
ED
AL P
OS
ITIO
N N
/C
SE
RV
ICE
BR
AK
E P
ED
AL P
OS
ITIO
N N
/C
(PE
DA
L R
ELE
AS
ED
PO
SIT
ION
)
6.5
mA
NO
TE
H
CR
UIS
E C
ON
TR
OL O
N/O
FF
6.5
mA
6.5
mA
6.5
mA
6.5
mA
6.5
mA
CH
EC
K E
NG
INE
LA
MP
WA
RN
ING
LA
MP
+B
AT
TE
RY
-BA
TT
ER
Y
J1587 D
LIN
K N
EG
AT
IVE
AT
A
J1587 D
LIN
K P
OS
ITIV
EA
TA
J1939 D
AT
A L
INK
Positiv
e
J1939 D
AT
A L
INK
Shie
ldJ1939 D
AT
A L
INK
Negative
D
H795-P
K
G CF
SA
E J
1939/1
3 O
FF
-BO
AR
DD
IAG
NO
ST
IC C
ON
NE
CT
OR
B A
TO
VE
HIC
LE
CO
MP
ON
EN
TS
CIR
CU
ITS
WIT
HIN
TH
IS A
RE
A A
RE
RE
CO
MM
EN
DA
TIO
NS
SIG
NA
L-
SIG
NA
L+
ST
AR
T
ON
OF
FB
SC R
H795-P
K
45.5mA MAX
GS
MT
RB
AT
ST
AR
TE
RM
OT
OR
(12V
)
BA
TT
ER
Y 2
N/O
RE
LA
Y
H795-P
KC
985-B
UC
986-B
R
C978-B
RC
979-O
R
C977-B
U
C992-P
U
C975-W
H
C973-G
N
C974-P
UK
EY
SW
ITC
H
659-P
K
GR
OU
ND
L994-Y
L
ALT
ER
NA
TO
R
-12V+
-12V+
+12V
-
BA
TT
ER
Y 3
BA
TT
ER
Y 1
NO
TE
F: IF
AN
ELE
CT
RO
NIC
SIG
NA
L IS
PR
OV
IDE
D IN
PLA
CE
OF
A P
AS
SIV
E
M
AG
NE
TIC
SE
NS
OR
, C
ON
NE
CT
TH
E E
LE
CT
RO
NIC
SIG
NA
L IN
PU
T T
O T
HE
+S
IGN
AL P
IN, T
HE
-S
IGN
AL P
IN S
HO
ULD
NO
T B
E C
ON
NE
CT
ED
O
R G
RO
UN
DE
D W
ITH
ELE
CT
RO
NIC
SIG
NA
L IN
PU
TS
NO
TE
D: T
HE
SE
CO
NN
EC
TIO
NS
AR
E U
NS
WIT
CH
ED
, D
IRE
CT
CO
NN
EC
TIO
N T
O T
HE
BA
TT
ER
Y IS
NO
T R
EQ
UIR
E
NO
TE
CN
OT
E F
LO
ME
D
HI
EN
GIN
E R
ET
AR
DE
RS
OL
EN
OID
SE
LE
CT
OR
SW
ITC
H
NO
TE
H
NO
TE
E: T
HE
EC
M S
PE
ED
OM
ET
ER
AN
D T
AC
HO
ME
TE
R O
UT
PU
T S
IGN
AL L
INE
V
OLT
AG
ES
AR
E Z
ER
O-C
RO
SS
ING
SQ
UA
RE
WA
VE
S. T
HE
SP
EE
DO
ME
TE
R S
IGN
ALS
AT
J1-3
7 A
ND
J1-3
6 A
RE
CO
MP
LE
ME
NT
S O
F E
AC
H O
TH
ER
. T
HE
TA
CH
OM
ET
ER
SIG
NA
LS
AT
J1-3
8 A
ND
J1-3
9 A
RE
CO
MP
LE
ME
NT
S O
F E
AC
H O
TH
ER
. M
AX
IMU
M S
IGN
AL A
MP
LIT
UD
E O
F J
1-3
6, J1-3
7,
J1-3
8, A
ND
J1-3
9 IS
+/-1
0 V
OLT
S. A
MP
LIT
UD
E W
ILL B
E
O
R G
RE
AT
ER
IF
LO
AD
CU
RR
EN
T IS
LE
SS
TH
AN
4m
A.
(PE
DA
L R
ELE
AS
ED
PO
SIT
ION
)
HI
TO
+B
AT
TE
RY
ME
D
LO
RE
TA
RD
ER
SO
LE
NO
ID O
N/O
FF
SW
ITC
H
13m
A
CO
OLIN
G F
AN
SO
LE
NO
ID
OU
TP
UT
#5
OU
TP
UT
#6
OU
TP
UT
#7
OU
TP
UT
#8
11
19
20
21
G837-Y
LG
838-B
RG
839-B
UG
840-P
U
229-B
K-B
AT
TE
RY
J H EA
249-B
KK
990-G
N
K900-Y
L
43
14 A
WG
GX
L
TO
CH
AS
SIS
J1939 D
AT
A L
INK
229-B
K
14 A
WG
GX
L 1
01-R
D
-BA
TT
ER
Y
UN
SW
ITC
HE
D +
BA
TT
ER
Y (
NO
TE
D)
14 A
WG
GX
L14 A
WG
GX
L
10A
10A
29
AppendixAppendix
C15 OEM Diagrams (2004)
C97
7-B
U E
716-
GY
G87
9-O
RC
983-
WH
C98
4-Y
L
CLU
TCH
PE
DA
L P
OS
ITIO
N S
WIT
CH
100m
A10
0mA
INP
UT
#11
(N
OTE
L)
INP
UT
#15
PO
SIT
IVE
RE
TAR
DE
R S
OLE
NO
ID L
OW
/HI S
WIT
CH
+5V
EN
GIN
E C
OO
LAN
T LE
VE
L N
OR
MA
L (N
OT
E G
)E
NG
INE
CO
OLA
NT
LEV
EL
LOW
(N
OT
E G
)R
ETA
RD
ER
SO
LEN
OID
ME
D/H
I SW
ITC
H
INP
UT
#15
NE
GA
TIV
EV
EH
ICLE
SP
EE
D IN
PO
SIT
IVE
(N
OT
E F
)V
EH
ICLE
SP
EE
D IN
NE
GAT
IVE
INP
UT
#8 (
NO
TE
L)
14 A
WG
GX
L14
AW
G G
XL
14 A
WG
GX
L
AC
CE
LER
AT
OR
PE
DA
L S
EN
SO
R/S
WIT
CH
SE
NS
OR
CO
MM
ON
+8V
AC
CE
LER
AT
OR
PE
DA
L P
OS
ITIO
N
2263 23 2 49 54 41 24E
971-
GN
G83
4-P
U
62 64 61
0.3A
CU
RR
EN
T L
IMIT
0.3A
CU
RR
EN
T L
IMIT
1 2
40 51 55
NO
TE
C: "
SIN
GL
E"
WIN
DIN
G M
AG
NE
TIC
PIC
KU
P S
EN
SO
R R
EC
OM
ME
ND
ED
NO
TE
B: F
OR
SP
EE
DO
ME
TER
S O
R T
AC
HO
ME
TE
RS
WIT
H A
SIN
GLE
SIG
NA
L IN
PU
T
T
ER
MIN
AL,
EIT
HE
R O
NE
OF
TH
E T
WO
SIG
NA
L O
UT
PU
T L
INE
S F
RO
M
T
HE
EC
M C
AN
BE
US
ED
. LE
AVE
TH
E R
EM
AIN
ING
LIN
E D
ISC
ON
NE
CT
ED
,
D
O N
OT
CO
NN
EC
T T
O G
RO
UN
D
5 4 6625 32 33 69 68
VE
HIC
LE H
AR
NE
SS
CO
NN
EC
TO
R
P2
J2
H79
5-P
KC
985-
BU
C98
6-B
R
L994
-YL
659-
PK
K99
8-B
UG
880-
PK
J906
-BR
G88
1-B
UG
882-
WH
SE
RV
ICE
BR
AK
E P
ED
AL
PO
SIT
ION
SW
ITC
H
INP
UT
#7
(NO
TE
L)
45C
992-
PU
INP
UT
SE
NS
OR
CO
MM
ON
#1
INP
UT
#5
(NO
TE
L)
INP
UT
#6
(NO
TE
L)
18 47 6 46
L901
-GY
G84
2-G
YG
843-
OR
G84
4-P
K
C97
4-P
UC
973-
GN
E71
8-P
KE
991-
GY
G83
6-W
H
CR
UIS
E C
ON
TR
OL
ON
/OF
F S
WIT
CH
INP
UT
#3
(NO
TE
L)
INP
UT
#4
(NO
TE
L)
59 60 7
C97
5-W
HK
982-
YL
G84
1-G
N
SE
TR
ES
UM
EIN
PU
T #
1 (N
OT
E L
)IN
PU
T #
2 (N
OT
E L
)
35 44 56 58
C97
8-B
RC
979-
OR
K99
9-G
NK
980-
PK
P1
J1
G83
5-O
RG
808-
BU
G80
9-G
N G
845-
PU
J158
7 D
ATA
LIN
K N
EG
ATI
VE
J158
7 D
ATA
LIN
K P
OS
ITIV
EJ1
939
DA
TA L
INK
SH
IEL
D (
NO
TE
K &
NO
TE
M)
J193
9 D
ATA
LIN
K N
EG
ATI
VE
(N
OTE
K &
NO
TE M
)J1
939
DA
TA L
INK
PO
SIT
IVE
(N
OT
E K
& N
OT
E M
)
UN
SW
ITC
HE
D +
BA
TTE
RY
(N
OT
E D
)U
NS
WIT
CH
ED
+B
AT
TER
Y (
NO
TE
D)
-BA
TT
ER
Y
INP
UT
#9
INP
UT
#10
INP
UT
SE
NS
OR
CO
MM
ON
#2
INP
UT
#14
52 53 65 6727 26 3 17
E71
7-G
N
101
-RD
101
-RD
229
-BK
G93
3-Y
L
C45
3-Y
L
993
-BR
F71
3-O
R
9 8 42 34 50 1 14 48
TAC
HO
ME
TE
R P
OS
ITIV
ETA
CH
OM
ET
ER
NE
GA
TIV
E38 39 57
450
-YL
451
-BR
SP
EE
DO
ME
TE
R P
OS
ITIV
ES
PE
ED
OM
ET
ER
NE
GAT
IVE
OU
TP
UT
#2
OU
TP
UT
#3
OU
TP
UT
#4
36 37 10 12 13 15 1628 29 30 31 70
+/-
5 V
OLT
S
CH
EC
K E
NG
INE
LA
MP
WA
RN
ING
LA
MP
OU
TPU
T #1
OU
TPU
T #9
IGN
ITIO
N K
EY
SW
ITC
HIN
PU
T #
12IN
PU
T #
13
E79
3-B
UE
794-
YL
A24
9-B
KK
990-
GN
K90
0-Y
L
SP
EE
DO
ME
TE
RN
OT
E E
NO
TE
H
NO
TE B
AC
CE
LER
ATO
R P
ED
AL
PO
SIT
ION
SE
NS
OR
40m
A5m
A
BK
RD
WH J4
03 P
403
AC
CE
LER
AT
OR
PE
DA
L S
EN
SO
R/S
WIT
CH
SE
NS
OR
CO
MM
ON
+8
VA
CC
ELE
RAT
OR
PE
DA
L P
OS
ITIO
N
B A C
H79
5-P
K
H79
5-P
K
A/C
HIG
H P
RE
SS
. SW
ITC
H N
/C
E97
1-G
N
450-
YL
451-
BR
SIG
NA
L+
SIG
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Appendix
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4289
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RES
PON
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60 D
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All i
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with
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7SA
743
0308
Cop
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TO O
IS
TAR
TER
RE
LAY
TO V
EH
ICLE
DIG
ITA
LO
UTP
UT
WIR
ING
8 9 10
RE
LATI
VE
HU
MID
ITY
/TC
IS
EN
SO
RC
ON
NE
CTO
RFC
/AP
EX
P/N
: 542
0040
9TE
RM
INA
L (G
OLD
)P
/N: J
TP-1
811-
66A
U
DDD-XXXXXXX
GN
D (V
PO
D G
ND
)IG
N (V
PO
D P
OW
ER
)S
EN
SO
R R
ETU
RN
RE
LATI
VE
HU
MID
ITY
SE
NS
OR
SU
PP
LYO
I STA
RTE
RTU
RB
O C
OM
P IN
LET
DIG
ITA
L O
UTP
UT
Y-3
DIG
ITA
L O
UTP
UT
X-3
DIG
ITA
L O
UTP
UT
W-3
CO
NN
EC
TOR
(10-
PIN
)A
PE
X P
/N: 5
4201
016
TER
MIN
AL
AP
EX
P/N
: LS
P-1
811-
58A
U
12
3
A B F G H J K
31
AppendixAppendix
DDEC V Vehicle Interface HarnessG
OV
ER
NO
R
C B AC B A
4010
6
MU
ST
PR
OV
IDE
IGN
ITIO
N P
OW
ER
IN R
UN
AN
D C
RA
NK
MO
DE
S.
DO
NO
T S
OU
RC
E A
NY
NO
N-D
DE
CA
CC
ES
SO
RY
FRO
M IG
N C
IRC
UIT
(V-1
5)
V-11
V-14
V-60
SE
NS
OR
SU
PP
LY #
1
VS
G
SE
NS
OR
RE
TUR
N #
1
CAV
ITY
V-11
V-13
V-60
LAB
EL
SE
NS
OR
SU
PP
LY #
1
ALS
G
SE
NS
OR
RE
TUR
N #
1
CAV
ITY
V-61
V-62
V-65
V-66
LAB
EL
BAT
TER
Y (+
)
BAT
TER
Y (+
)
BAT
TER
Y (+
)
BAT
TER
Y (+
)
AM
BE
R W
AR
NIN
G L
AM
PR
ED
STO
P LA
MP
SE
RV
ICE
BR
AK
E R
ELE
AS
ED
FAN
CO
NTR
OL
#1D
IGIT
AL
OU
TPU
TD
IGIT
AL
OU
TPU
TV
EH
ICLE
PW
R S
HU
TDO
WN
RE
SU
ME
/AC
CE
LC
RU
ISE
EN
AB
LEC
LUTC
H R
ELE
AS
ED
SE
NS
OR
SU
PP
LY #
1S
EN
SO
R S
UP
PLY
#2
THR
OTT
LE P
OS
ITIO
NV
SG
IGN
ITIO
NID
LE V
ALI
DAT
ION
VE
HIC
LE S
PE
ED
SE
NS
OR
(+)
VE
HIC
LE S
PE
ED
SE
NS
OR
(-)
NO
CO
NN
EC
TIO
NN
O C
ON
NE
CTI
ON
NO
CO
NN
EC
TIO
NA
IR F
ILTE
R R
ES
TRIC
TIO
NE
XH
AU
ST
TEM
PE
RAT
UR
ES
EO
/DIA
G R
EQ
UE
ST
A/C
STA
TUS
AN
ALO
G IN
PU
T - 1
.5kΩ
PU
LLU
PTU
RB
O C
OM
PR
ES
SO
R IN
TE
MP
NO
CO
NN
EC
TIO
NE
XH
AU
ST
BA
CK
PR
ES
SU
RE
OR
FIR
E T
RU
CK
PU
MP
PR
ES
SU
RE
NO
CO
NN
EC
TIO
NTA
CH
OM
ETE
RFR
EQ
UE
NC
Y - S
PAR
EFR
EQ
UE
NC
Y - S
PAR
EN
O C
ON
NE
CTI
ON
NO
CO
NN
EC
TIO
NN
O C
ON
NE
CTI
ON
AD
D C
OO
LAN
T LE
VE
LC
OO
LAN
T LE
VE
L - S
HU
TDO
WN
EN
GIN
E B
RA
KE
LO
WO
I ALA
RM
AU
X S
HU
TDO
WN
#1
OI T
HE
RM
OS
TAT
J 19
39 D
L (+
)J
1939
DL
SH
IELD
NO
CO
NN
EC
TIO
NP
WM
OU
TPU
TS
ET/
CO
AS
TA
NA
LOG
INP
UT
- 1.5
kΩ P
ULL
UP
FAN
CO
NTR
OL
OV
ER
RID
EPA
RK
BR
AK
EE
NG
BR
AK
E M
ED
PW
M O
UTP
UT
ETH
ER
STA
RT
OI S
TAR
TER
OI A
CTI
VE
LA
MP
J 15
87 +
J 15
87-
J 19
39 D
L (-
)S
EN
SO
R R
ETU
RN
#2
SE
NS
OR
RE
TUR
N #
1+1
2V /
+24V
+12V
/ +2
4VB
ATTE
RY
GR
OU
ND
BAT
TER
Y G
RO
UN
D+1
2V /
+24V
+12V
/ +2
4VB
ATTE
RY
GR
OU
ND
BAT
TER
Y G
RO
UN
D
LAB
EL
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
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
CAV
ITY
PO
WE
R W
IRIN
G
V-63
V-64
V-67
V-68
BAT
TER
Y (-
)
BAT
TER
Y (-
)
BAT
TER
Y (-
)
BAT
TER
Y (-
)
V-15
SW
ITC
HE
DIG
NIT
ION
BAT
TER
Y (-
)
IGN
ITIO
NFU
SE
BAT
TER
Y (+
)30
AM
P
CAV
ITY
V-5
V-6
V-52
V-46
V-48
V-11
V-60
V-26
V-11
V-60
LAB
EL
LOW
SID
E D
IGIT
AL
OU
TPU
T
LOW
SID
E D
IGIT
AL
OU
TPU
T
PW
M O
UTP
UT
PW
M O
UTP
UT
INP
UT
SE
NS
OR
SU
PP
LY #
1*IN
PU
T W
ITH
1.5k
Ω P
ULL
-UP
SE
NS
OR
RE
TUR
N #
1
CAV
ITY
SPA
RE
DIG
ITA
L &
PW
M O
UTP
UTS
/INP
UTS
DD
EC V
VEH
ICLE
INTE
RFA
CE
HA
RN
ESS
68-W
AY C
ON
NE
CTO
RD
DC
P/N
: 235
2825
214
AW
G T
ER
MIN
AL
DD
C P
/N: 2
3528
272
AU
TOM
OTI
VE
LIM
ITIN
GS
PE
ED
GO
VE
RN
OR
VAR
IAB
LES
PE
ED
GO
VE
RN
OR
(OP
TIO
NA
L)
IDLE
VALI
DAT
ION
(RE
QU
IRE
D)
All i
nfor
mat
ion
subj
ect t
o ch
ange
with
out n
otic
e. (R
ev. 6
/05)
7SA
821
050
6 C
opyr
ight
© 2
005
DET
RO
IT D
IESE
L C
OR
POR
ATIO
N
55 40
2516 1 10
41 45
30
56 6015
68
61 64
26 11
6546 31
INP
UT
SE
NS
OR
SU
PP
LY #
1*IN
PU
T W
ITH
1.5k
Ω P
ULL
-UP
SE
NS
OR
RE
TUR
N #
1
* N
OT
US
ED
FO
R D
IGIT
AL
INP
UTS
RE
SIS
TOR
S A
RE
INTE
RN
AL
TO E
CU
V-16
V-59
IDLE
VA
LID
ATIO
N
SE
NS
OR
RE
TUR
N #
2
CAV
ITY
DA
SH
PA
NE
L
V-9
RE
TUR
N
SIG
NA
L
VE
HIC
LE S
PE
ED
SE
NS
ORO
NO
FF
ON
OFFON
OFF
ON
OFF ON
OFF
CLU
TCH
SW
ITC
H
SE
T/C
OA
ST
SW
ITC
H
RE
SU
ME
/AC
CE
LS
WIT
CH
CR
UIS
EE
NA
BLE
SW
ITC
H
LAB
EL
CR
UIS
E C
ON
TRO
L
THR
OTT
LE P
ED
AL
OP
TIM
IZE
D ID
LE (O
PTI
ON
AL)
V-8
V-47
V-55
OI A
CTI
VE
LA
MP
+12/
24V
V-54
OI S
TAR
TER
+12/
24V
V-3
V-10
V-59
V-17
V-18
SE
NS
OR
RE
TUR
N #
2
V-40
O
I ALA
RM
V-42
O
I TH
ER
MO
STA
T
(RE
FER
TO
OP
TIM
IZE
D ID
LE F
OR
RE
LAY
RE
QU
IRE
ME
NTS
)
+12/
24V
TO P
IN D
OF
THE
RM
OS
TAT
CO
NN
EC
TOR
V-24
V-59
INS
TRU
ME
NT
PAN
EL
DIA
GN
OS
TIC
CO
NN
EC
TOR
CAV
ITY
- -V-
43V-
58V-
44V-
56V-
57 - -
LAB
EL
GN
D+1
2/24
VJ
1939
DAT
A LI
NK
(+)
J 19
39 D
ATA
LIN
K (-
)J
1939
SH
IELD
J 15
87 D
ATA
LIN
K (+
)J
1587
DAT
A LI
NK
(-)
PLU
GP
LUG
CAV
ITY
V-27
V-59
LAB
EL
DD
C C
ON
NE
CTO
R
A B C D E F G H J
TUR
BO
CO
MP
RE
SS
OR
IN T
EM
P
MA
INTE
NA
NC
E A
LER
T S
YS
TEM
ON
LY
CO
AC
H A
PP
LIC
ATIO
NS
ON
LY
RE
D S
TOP
LAM
P
AM
BE
R W
AR
NIN
G L
AM
P
IGN
IGN
+12/
24V
FAN
CO
NTR
OL
- SIN
GLE
SP
EE
D F
AN
LAB
EL
RS
L
AWL
TAC
H O
UTP
UT
CAV
ITY
V-02
V-01
V-31
EN
GIN
E B
RA
KE
SW
ITC
HE
S
DIA
GN
OS
TIC
RE
QU
ES
T / S
TOP
EN
GIN
E O
VE
RR
IDE
A/C
STA
TUS
FAN
CTR
L O
VE
RR
IDE
SE
NS
OR
RE
TUR
N
V-25
FAN
CO
NTR
OL
#1
V-4
V-49
V-59
CO
NN
EC
TOR
DE
UTS
CH
P/N
: HD
10-9
-193
9PD
DC
P/N
: 235
2949
6
TER
MIN
AL
DE
UTS
CH
P/N
: 046
0-20
2-16
141
DD
C P
/N: 2
3507
132
DIA
GN
OS
TIC
RE
Q/
SE
O S
WIT
CH
V-11
SE
NS
OR
SU
PP
LY #
1
AIR
FILT
ER
RE
STR
ICTI
ON
AIR
FIL
TER
RE
STR
ICTI
ON
SE
NS
OR
RE
TUR
N #
1
V-22
V-60
A B C
V-60
SE
NS
OR
RE
TUR
N #
1
FIR
E T
RU
CK
PU
MP
PR
ES
SU
RE
SE
NS
OR
SU
PP
LY #
1
PU
MP
PR
ES
SU
RE
V-11
V-29
A B C
V-60
SE
NS
OR
RE
TUR
N #
1
EX
HA
US
TB
AC
KP
RE
SS
UR
EE
XH
AU
ST
BA
CK
PR
ES
SU
RE
SE
NS
OR
SU
PP
LY #
1
V-29
V-11
1 2 3
V-60
SE
NS
OR
RE
TUR
N #
1E
XH
AU
ST
TEM
PE
RAT
UR
EE
XH
AU
ST
TEM
PE
RAT
UR
EV-
23
A B
TUR
BO
CO
MP
RE
SS
OR
IN T
EM
P
2 1
PAR
K B
RA
KE
SE
NS
OR
RE
TUR
N
V-59
V-50
EN
G. B
RA
KE
LO
W
EN
G. B
RA
KE
ME
D
SE
NS
OR
RE
TUR
N
DIA
G R
EQ
/SE
O
SE
NS
OR
RE
TUR
N
V-39
V-51
V-59
PAR
KIN
G B
RA
KE
& V
EH
ICLE
PO
WE
R S
HU
TDO
WN
TCI
SE
NS
OR
RE
TUR
N #
2
CAV
ITY
V-38
V-60
LAB
EL
EN
GIN
E C
OO
LAN
T LE
VE
L S
EN
SO
R -
SH
UTD
OW
N
CO
OLA
NT
LEV
EL
SE
NS
OR
S
HU
TDO
WN
A B
CO
OLA
NT
LEV
EL
SE
NS
OR
RE
TUR
N
CAV
ITY
V-37
V-60
LAB
EL
AD
DC
OO
LAN
TLE
VE
LA B
AD
D C
OO
LAN
T LE
VE
L
SE
NS
OR
RE
TUR
N
CAV
ITY
PLU
GD
EU
TSC
H P
/N: 1
1401
7D
DC
P/N
: 235
0713
6
CO
NN
EC
TOR
CO
VE
RD
EU
TSC
H P
/N: H
DC
16-9
D
DC
P/N
: 235
2949
7
18 A
WG
TE
RM
INA
LD
DC
P/N
: 235
2827
1
+12/
24V
DIG
ITA
L O
UTP
UT
SE
RV
ICE
BR
AK
ES
WIT
CH
IGN
VE
HIC
LE P
OW
ER
SH
UTD
OW
N
V-7
SH
RO
UD
SID
EO
F C
ON
NE
CTO
R
32
33
Appendix
Torque Specifications
* Thread adhesive sealant required.
Part Torque
Flywheel capscrews Follow engine manufacturer’s specifications
Transmission-to-Engine capscrews
7/16-14 * 37 - 50 lbs. ft. [50 - 68 N•m]
3/8-16 * 25 - 32 lbs. ft. [34 - 43 N•m]
M10 x 1-3/8 * 26 - 35 lbs. ft. [35 - 47 N•m]
M10 x 1-3/4 * 26 - 35 lbs. ft. [35 - 47 N•m]
Output yoke nut 450 - 500 lbs. ft. [610 - 678 N•m]
PTO mounting capscrews:
6-bolt opening * 20 - 25 lbs. ft. [27 - 34 N•m]
8-bolt opening * 50 - 65 lbs. ft. [68 - 88 N•m]
Reverse switch (9/16-18) 20 - 25 lbs. ft. [27 - 34 N•m]
Neutral switch/cap (3/4-16) 20 - 25 lbs. ft. [27 - 34 N•m]
Speedometer electronic sensor (3/4-16) 10 - 15 lbs. ft. [14 - 20 N•m]
Lubricant fill plug (1¼-NPT) 60 - 75 lbs. ft. [81 - 101 N•m]
Lubricant drain plug (3/4-NPT) 45 - 55 lbs. ft. [61 - 75 N•m]
Lifting bracket capscrew (3/8-16) 35 - 45 lbs. ft. [47 - 61 N•m]
Rear bearing cover capscrew (3/8-16) 35 - 45 lbs. ft. [47 - 61 N•m]
Transmission nodal mount capscrews (3/4-10) 180 - 190 lbs. ft. [244 - 258 N•m]
Transmission rear support stud nuts (5/8-18) 170 - 185 lbs. ft. [230 - 250 N•m]
Range Air Valve Mounting Screw (#10-24) 21 - 27 lbs. in. [2 - 3 N•m]
34
AppendixAppendix
Suggested Tools
Related Publications
For additional information call the Roadranger Call Center at 1-800-826-HELP (4357).
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.
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-0670 - RTLO 13-speed Models
TRDR-0800 - RTLO 18-speed Models
TRDR-3349 - Convertible Models
Lubrication Requirements TCMT-0020 - Roadranger Products Approved Lubricants
TCMT-0021 - Roadranger Products Lubrication Manual
Appendix
Application Forms
Eaton® Fuller® Transmissions
Form FUL-169
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 FUL-170 (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/s2 . • 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.
• 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.
NOTE 2
Max Gross H.P.
Max. Peak Torque
lbs-ft
TransmissionSeries
GCW limit for Blanket Approval
MaximumDriveline
250 RT-6609-A 74,000 Lbs. 9,700
860
RT-8908-LL
RT-8709-B
300
950
1050
80,000 Lbs.
All Other 11XXX
12,500
1150 RTO-11909-XLL 17,500
1250
370
1350
400 T-14607
90,000 Lbs.
15,500
450 1450 All Other 14XXX
500 15XXX
1650
1750
600 1850
140,000 Lbs.
2050 RTLO-20913/18
700 2250150,000 Lbs.
17,500
2-A-92 9,700
AT-1202 17,500
NOTE 1 — “A” calculation A1 or A2 must be less than “A ” A1 = Peak Engine Torque x Lowest Gear Ratio A2 = 672 x W M x AR
Where: W =Weight on drive wheels — Lbs. M =Tire revolution per mile AR =Axle ratio
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 250°F at worst case operating conditions.
Additional Application Requirements for Approval of RTLOC-1X909A-T2:• Application must be for On-Highway 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.
• 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.
On-Highway is defined as limited access and general highways. Grades less than 8%, well maintained, concrete or asphalt surface, no more than 10% off-highway operation. Maintained gravel, crushed rock, hard packed dirt or similar road surfaces are acceptable when grades are less than 3%.
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.
11/03
RT-8608-L
FR-9210B
10XXX
12XXX
13XXX
16XXX
17XXX
18XXX
RTLO-22918
660
1400
1550
• 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.
• 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.
NOTE 2 — "A" calculation for Auxiliaries
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.
Torque, "A"
3 3 3, 4 1
5
5
4
35
AppendixAppendix
Eaton® Fuller
®
Transmissions
Application Approval Form FUL-170 – Rev. 01/04
Approval I.D. No.:
Chassis #(s):
No. of Vehicles:
Projected Build Date:
OEM / Plant Location: /
Customer/Fleet:
Dealer Information
Dealership Name:
Dealer Address:
Contact:
Telephone: FAX:
APPROVAL REQUEST FOR: Transmission Model Oil Cooler: YES NO
ENGINE INFORMATION:
Make: Model: Displacement: Liters
Rated Horsepower at RPM Peak Torque Lbs-ft at RPM
Governed Speed: RPM Top Speed Limit Setting MPH Cruise Speed MPH
DRIVELINE INFORMATION:
Rear Axle Make: Model: Ratios: /
Drive Tires Make: Model: Size: or Revs/Mile
Retarder Make: Model: Type: HP
Clutch Make: Model:
Make: Model: Ratios: / Trans Case /Aux. Trans
CHASSIS INFORMATION
Model: Drive Configuration (6x4, 4x2) Vehicle Voltage (12 or 24v) 12 V
Max Weight on Drive Wheels Lbs Max GVW Lbs Max GCW Lbs
VOCATIONAL AND BODY SPECIFIC INFORMATION:
Vocation (Line Haul, Dump, Refuse, Mixer, etc)
Body Type Trailer Type # Trailers
Area of Operation: Country(s) State / Province/Region
Road Usage: Highway % Secondary/City % Off-Highway % Off-Road %
Maximum Grade on Which Vehicle will be Required to Operate %
TRANSMISSION FEATURE / OPTION REQUIREMENTS: (CHECK BOX OF APPROPRIATE CONFIGURATION)
PTO Usage: None 6 Bolt Engine Split-Shaft Countershaft: 6 Bolt 8 Bolt Aux
PTO Model: PTO Driven Equipment:
PERSON SUBMITTING REQUEST PHONE: FAX:
FIRM NAME & ADDRESS:
THIS APPLICATION IS:
ADDITIONAL NOTES / REQUIREMENTS:
SIGNED: APPLICATION ENGINEER: DATE:
1. 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.
2. All Eaton warranty guidelines apply for coverage and specific labor repair times. Reference Eaton publications TCWY-0600 and TCWY-0900.
3. Refer to form FUL-169 ( ) for Blanket Application Requirements.
Eaton Corporation – TOA
P.O. Box 4013
Kalamazoo, MI 49003
Phone: (269) 342-3000
Fax: (269) 342-3574
36
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
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©20 07 Eaton Corporation · All rights reserved.Pr inted in US A
Copyright Eaton and Dana Corporation,2007. EATON AND DANA CORPORA TIONhereby grants its customer s, vendor s, ordistributor s permission to freely copy,reproduce and/or distribute this documentin printed format. It may be copied only in itsentirety without any changes or modifications.THIS INFORMATION IS NOT INTENDEDFOR SALE OR RESALE, AND THIS NOTICEMUST REMAIN ON ALL COPIES.