Eaton AT-1202 Installation Manual Download

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Inertia Brake

Ine
rtia Brake

Remove Left Side Inertia Brake

Disconnect harness at 2 connector locations and remove ty-raps from inertia brake.

Note:

Take care not to damage harness. Protect connector ends from dirt contamination.

Disconnect oil hose from inertia brake and transmission case.

Remove (6) mounting bolts from the inertia brake.

CAUTION

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

There may be some residual oil in the inertia brake.

Remove the inertia brake, spacer plate, and gaskets from the transmission.

Note:

Clean and remove all old gasket material from the mating surfaces of the inertia brake and transmission PTO openings.

Note:

Some transmissions may not use a spacer plate with the inertia brake.

Remove the 90º fitting and filter fitting from transmission case that was connected to the oil supply hose.

90deg fitting
and filter
fitting

Remove Right Side PTO Cover

Remove (6) bolts from the right side PTO cover.

Remove cover

Note:

Clean and remove all old gasket material from the mating surfaces of the PTO cover and opening on the transmission case.

Summary of Contents for AT-1202

Page 1: ...Installation Guide Eaton PTOInformationGuide TRIG2600 EN US August 2017 ...

Page 2: ...r 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 Warning Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician Caution Failure to follow indicated procedures may cause component damage or...

Page 3: ...traShift PLUS and FA PTO Inputs and Configurations 35 Countershaft Thru Shaft and Split Shaft PTOs 35 PTO Configurations 36 UltraShift PLUS Auto Neutral Feature 36 Endurant PTO Inputs and Configurations 37 PTO System Engagement Sequence 37 Endurant Auto Neutral Feature 37 PTO Wiring Diagrams 38 Medium Duty Hybrid PTO Inputs and Configuration 42 Countershaft PTOs 42 Medium Duty Dual Clutch PTO Inpu...

Page 4: ...equirements Thru Shaft Thru Shaft design for Fuller transmissions Three speed ratios available Two shift options available Direct mount pump flanges or driveshaft output options Note Thru Shaft is a PTO option that must be specified when ordering the vehicle Rear Mount Extended Countershaft Fits Fuller transmission that have the extended countershaft option Three speed ratios available Comes stand...

Page 5: ...g additional PTO openings Several 6 Bolt and Reversible PTOs will fit on the 912 Series Three 8 Bolt openings that allow you to operate a variety of auxiliary equipment Wide variety of 6 Bolt 8 Bolt PowerShift and Reversible PTOs fit the 912 Series Air and Lever shift available Split shaft PTOs can be used on all heavy duty Fuller manual UltraShift PLUS and AutoShift transmis sions Medium duty wet...

Page 6: ...ic mounts Air shift operation Suitable for stationary or mobile applications Precision ground gearing for quiet operation Split shaft PTOs can be used on all heavy duty Fuller manual UltraShift PLUS and AutoShift transmis sions Medium duty wet clutch transmissions will have split shaft PTO capability with the spring 2006 software release All other automated products do not have the ability to oper...

Page 7: ...gears as the 442 and 489 Series Uses the same mounting hardware and spacers used to mount a 442 Series to a specific application 628 Series Mounts a 6 Bolt PTO to a 6 Bolt transmission opening Moves the PTO straight out from the transmission Uses the same input gears as the 442 and 489 Series Uses the same mounting hardware and spacers used to mount a 489 Series to a specific application ...

Page 8: ...ing is needed for PTO usage this 30 adapter allows the movement of the high capacity inertia brake from the 8 Bolt opening to the 6 Bolt opening and rotates the high capacity inertia brake to eliminate interference problems 645 Series Mounts a 6 Bolt PTO to a 6 Bolt transmission opening Moves the PTO down at a 45 angle helping to eliminate interference problems Uses the same input gears as the 442...

Page 9: ... flange outward away from the transmission Angular Adapters Various angles available 55 adapter available for relocating high capacity inertia brake on heavy duty Fuller UltraShift transmis sions 8 Bolt to 6 Bolt Adapter Converts an 8 Bolt PTO opening into a 6 Bolt PTO opening ...

Page 10: ...7 PTO Adapters Angular Offset Gear Adapter Offered in multiple gearing configurations All adapters offered with a 10 offset ...

Page 11: ...eeth 6 35P N A N A N A 26 Teeth 52 FS 6305A N A N A Right Left 39 Teeth 6 35P N A N A N A 26 Teeth 46 FS 6305B N A N A Right Left 41 Teeth 6 5P N A N A N A 26 Teeth 46 FS 6406A N A N A Right Left 38T 6 35P 22DEG R H HELIX N A N A N A 26T 45DEG PA 52 FSB 5406B N A N A Right Left 38T 6 35P 22DEG R H HELIX N A N A N A 26T 45DEG PA 52 FSB 6406B N A N A Right Left 38T 6 35P 22DEG R H HELIX N A N A N A ...

Page 12: ...B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTX 13609B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTX 14609B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTX 16709B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 T 14607A Yes 47T 6 0P 20D...

Page 13: ...2T 0 5P 30DEG PA N A N A 94 RTO 14909ALL Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left2 32T 0 5P 30DEG PA N A N A 79 RTO 14915 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A 32T 0 5P 30DEG PA N A N A 89 RTO 16908LL Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left2 32T 0 5P 30DEG PA N A N A 94 RTO 16909ALL Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left2 32T 0 5P 30DEG PA...

Page 14: ...Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 20918B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 22918B Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 5006 RTLOC 16909A T2 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 3505 RTLOC 18909A T2 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 5006 RTOC 16909A Yes 47T 6 0P 20DEG ...

Page 15: ...EG PA N A N A 79 FAOM 16810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 11810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 12810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 13810C Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA 32T 0 5P 30DEG PA N A N A 79 FAO 14810C Yes 47T 6 0P 20DEG PA Yes4 45T ...

Page 16: ... 65 FRW 15210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 65 FRM 15210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 87 FR 9210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 65 FRO 11210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 87 FRO 11210C Yes 47T 6 0P 20DEG PA Y...

Page 17: ...2T 0 5P 30DEG PA N A N A 87 FRO 15210C Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 84 FRO 16210B Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 87 FRO 16210C Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 84 FRO 17210C Yes 47T 6 0P 20DEG PA Yes9 45T 6 0P 20DEG PA LL UR 32T 0 5P 30DEG PA N A N A 84 FRO 1821...

Page 18: ...Ext Aux Counter shaft PTO Ext Spline Info of Engine Speed Transmission TorqueLimitfor PTO use lb ft AT 1202 Yes 30T 5 0P 20DEG PA Yes 30T 5 0P 20DEG PA N A N A N A N A 93 5006 2A 92 No N A No N A N A N A N A N A N A N A Note 6 Intermittent torque of up to 750 lb ft at the countershaft is permitted for 5 minutes of each 15 minute PTO duty cycle ...

Page 19: ...lable Default UltraShift HV N A Available Default N A AutoShift Available Available Default N A UltraShift DM3 N A Available Default N A Fuller Advantage Available Available Default Available Default UltraShift PLUS Available Available Default Available Default Endurant N A Available Default Available Default Note Thru Shaft extended countershaft and extended auxiliary countershaft PTO availabilit...

Page 20: ... N A N A Left or Right2 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 6506B DM3 N A N A Left or Right2 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 6406A ASX N A N A Right Only 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 8406A ASX N A N A Right Only 48T 7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 FO 6406A AW3 N A N A Right Only 48T 7 00P 26DEG R H HELIX N ...

Page 21: ...t 7 EDCO 6F107A N A L 23T LH Helix 5 64P 20DEG PA R 47T RH Helix 8 975P 17DEG PA Left or Right 45T 6 0P 20DEG PA N A N A Yes 400mm 12T 20DEG PA L 39 R 82 500 EDCO 6F107A P N A Left or Right 45T 6 0P 20DEG PA N A N A Yes EDCO 6F107A M N A Left or Right 45T 6 0P 20DEG PA N A N A Yes EDCO 6F107A B N A Left or Right 45T 6 0P 20DEG PA N A N A No N A Note 7 Minimum Engine Speed 1100 RPM Includes all PTO...

Page 22: ... 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8E406A P N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8FA0406A PSB N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8E406A T N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH 8E406A UP N A N A Left or Right 48T7 00P 26DEG R H HELIX N A N A Yes 26T 45DEG PA 67 EH...

Page 23: ...er Left 32T 0 5P 30DEG PA N A N A 79 5006 FO 14E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FOM 14E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FOM 14E310C VAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FM 14E310B LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG...

Page 24: ...t 32T 0 5P 30DEG PA N A N A 79 FOM 16E310C LAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FOM 16E310C VAS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 RTO 16910B AS3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 94 3505 RTO M 16910B DM3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA ...

Page 25: ...0 5P 30DEG PA N A N A 79 FAOM 15810C EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAOM 16810C EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAM 14810B EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAM 15810B EA3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32...

Page 26: ... 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAOM 15810S EN3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FAO 16810S EN3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 23 PTO Configurations Note 4 6 bolt PTO will interfere with front mount oil filter Rear or remote mount oil filter must b...

Page 27: ... N A N A 94 FO 17E308LL VCS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 94 FO 10E309ALL VMS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FO 11E309ALL VMS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 30DEG PA N A N A 79 FO 12E309ALL VMS Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA Lower Left 32T 0 5P 3...

Page 28: ...318B MXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 FO 16E318B VXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO M 16913L DM3 N A3 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 350 FO M 16D313E LEP N A3 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 16918A AS3 Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79...

Page 29: ...6 0P 20DEG PA N A N A N A N A 79 350 FO 20E313A MHP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 5006 FO 20E313A VHP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 FO 20E318B MXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 FO 20E318B VXP Yes 47T 6 0P 20DEG PA Yes4 45T 6 0P 20DEG PA N A N A N A N A 79 RTLO 20918A AS3 Yes 47T 6 0P 20DEG PA Yes4...

Page 30: ...eed Transmission Power Limit for PTO Use HP EEO 14F112C Yes1 42T 3 156 MODULE 20DEG PA 28 9747 DEG H A LEFT HAND 137 Opposite of Engine 95 HP 950 RPM min EEO 15F112C EEO 16F112C EEO 17F112C EEO 18F112C Note 1 Elastomer controlled squeeze seal required at PTO Transmission mounting surface ...

Page 31: ...SAE J1455 Convoluted Conduit shall have a service temperature of at least 257 F 125 C Braided Loom shall have a service temperature of at least 280 F 138 C Coverage A minimum of 10 maximum of 12 picks per inch TWISTED CABLES 2 Cables 10 Twists 25 4 cm 3 Cables 8 Twists 25 4 cm 16 and 18 Gage Cable Only SAE Wire Size mm2 SAE Wire Size No Nominal Outside Diameter mm Nominal Outside Diameter in TXL G...

Page 32: ...ile R 69246 round Convo luted Tubing Size 13 mm 500 125 C or higher temperature rating 29 Cable Configuration Note Eaton recommended component Recommended Bend Radius 6 X Hardness Diameter Inch Metric mm Diameter Bend Radius Diameter Bend Radius 3 16 0 188 1 1 5 29 1 4 0 250 1 5 6 38 3 8 0 375 2 3 10 57 1 2 0 500 3 0 13 76 5 8 0 625 3 8 16 95 3 4 0 750 4 5 19 114 1 1 1 000 6 0 25 152 Contact Lubri...

Page 33: ...ign compound shall be applied to the connector jackscrew threads The use of such compounds may affect jackscrew torque and prevent proper sealing of the connector The recommended minimum material volume for the MetricPack 150 speed sensor contact is 0 004 CC per socket The recommended minimum material volume for the Deutsch size 20 contact is 0 004 CC per socket The recommended minimum material vo...

Page 34: ...ive the transmission main box countershaft Incorrect or no PTO interface signal to the transmission will result in no clutch activation and therefore no PTO operation The active signal will illuminate the Mode indicator on the push button console The transmission default mode for the pin F1 input is for countershaft PTO operation If the push button console is programmed for something other than co...

Page 35: ...hicle is stopped i e stationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch opened normal transmission gear engagement can be selected The Fuller AutoShift ASW transmission must have an input signal from the device to activate this feature The input signal wires must be isolated from other related circuits Switch A1 A2 A3 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1...

Page 36: ...d no enabling of the countershaft PTO feature is required unless the push button console change to TECU was previously programmed for split shaft PTO operation The input signal wire for the PTO must be isolated from other PTO related circuits The connector must be compatible with 18 TXL wire The ground connection must be isolated from local power device ground returns Frame rail ground is not reco...

Page 37: ...switch closed this feature causes the transmission to neutralize when the vehicle is stopped i e stationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch opened normal transmission gear engagement can be selected The Eaton UltraShift AW3 transmission must have an input signal from the device to activate this feature The input signal wire for Auto Neutra...

Page 38: ... for correct wire and terminal pin sizes for communication and control wires PTO input shall be a normally open switch The switch shall close to the PTO return line pin 34 whenever the PTO is activated This input activates the PTO mode of the transmission This feature uses pin 18 and 34 of the transmission connector see illustration The input signal wire for the PTO shall be isolated from other PT...

Page 39: ...d to reflect Split Shaft PTO The Eaton ServiceRanger tool is the recommended interface for changing the configuration setting UltraShift PLUS Auto Neutral Feature An auto neutral feature is provided with this transmission which forces the transmission into neutral in all instances when the parking brake is applied This requires the OEM to T a pressure switch into the existing air line to the parki...

Page 40: ...peration Examples of the three different types of integration are shown below PTO System Engagement Sequence Note This is not an operator sequence 1 The TCM will receive a PTO request from the vehicle to enter into a PTO mode 2 If the TCM conditions are validated for PTO operations 3 The TCM will supply a PTO engage output to allow the PTO engagement 4 A confirmation from the PTO returns to the TC...

Page 41: ...TO 11 12 J1939 PTO Installation with Hardwire Confirm Module 2 OEM ECU sends the Request message via J1939 to the TCM J 1939 Battery Voltage Ground Switched Ground Solenoid Driver Air Supply J1939 PTO Control with Hardwire Confirm From To Description Notes PTO Switch OEM ECU PTO Request Hardwired OEM ECU TCM PTO Request J1939 TCM OEM ECU PTO Engage J1939 OEM ECU OEM Module PTO Engage J1939 OEM Mod...

Page 42: ... to the TCM J 1939 Battery Voltage Ground Switched Ground Solenoid Driver Air Supply 6 J1939 Confirm message from OEM ECU to TCM to operate PTO 5 PTO Confirm to OEM ECU J1939 PTO Control From To Description Notes PTO Switch OEM ECU PTO Request Hardwired OEM ECU TCM PTO Request J1939 TCM OEM ECU PTO Engage J1939 OEM ECU OEM Module PTO Engage J1939 OEM Module PTO Solenoid Solenoid PWR 12 Volt PTO So...

Page 43: ...e posistion PTO with Confirm Switched to Chassis From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request Vbatt DPST SW03 PTO Power Vbatt should be fused to protect wiring to PTO and PTO DPST SW04 PTO Engage Relay 30 PTO Engage TCM B 5 PTO Engage Relay 86 PTO Engage PTO Engage Relay 85 TCM B 2 PTO Engage PTO Engage Relay 87 PTO PTO Power PTO Engage PTO PTO Ground Cha...

Page 44: ...15 5 14 4 13 3 12 2 11 1 16 15 14 2 5 PTO with Confirm Switched to Power From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request TCM B 5 PTO Engage Relay 86 PTO Engage PTO Engage Relay 85 TCM B 2 PTO Engage Vbatt DPST SW03 PTO Power Vbatt should be fused to protect wiring to PTO and PTO DPST SW04 PTO Engage Relay 30 PTO Engage PTO Engage Relay 87 PTO PTO Power PTO E...

Page 45: ...n 2 ePTO selection input comes from the Push Button Shift Control which is sent from the TECU over J1939 to the HCM The transmission will go to neutral and then the HCM will activate PTO pins 21 and 22 which enables the PTO The PTO switch is grounded whenever the PTO is activated This input active when pin 18 is shorted to ground verifies the countershaft PTO oper ation Note The active signal will...

Page 46: ...lus HCM 34 ePTO 18 PTO Power Minus HCM 6 ePTO 18 ePTO HCM J1939 Controlled Description From Pin To Pin AWG J1939 Low CAN HCM 2 J1939 Backbone 2 18 J1939 High CAN HCM 3 J1939 Backbone 3 18 mPTO HCM Controlled Description From Pin To Pin AWG PTO Signal HCM 19 mPTO PTO Grnd Switch 18 43 PTO Interface ...

Page 47: ...ion TCM has the functionality to support two PTOs at the same time one direct wire control and one over the J 1939 network PTO operation requires a single pole double throw switch Consult PTO manufacturer for power requirements needed for fuses switches and wires on PTO circuitry TCM Request and Confirmation circuit lines will provide 1 milliamp of current for both 12 volt and 24 volt vehicle syst...

Page 48: ...nactive posistion PTO with Confirm Switched to Chassis From To Description Notes TCM B 14 DPST SW01 PTO Request DPST SW02 TCM B 15 PTO Request Vbatt DPST SW03 PTO Power Vbatt should be fused to pro tect wiring to PTO and PTO DPST SW04 PTO Engage Relay 30 PTO Engage TCM B 5 PTO Engage Relay 86 PTO Engage PTO Engage Relay 85 TCM B 2 PTO Engage PTO Engage Relay 87 PTO PTO Power PTO Engage PTO PTO Gro...

Page 49: ...ND B 5 RTN_1 CHASSIS GROUND PTO w Confirm Switched to Power 30 87A 87 86 85 30 87 A 87 86 85 PTO Confirm Relay PTO Inside or on Dashboard TCM SW02 SW04 SW03 SW01 DPST L L PTO Power PTO Ground PTO Confirm Contact Customer Support Engineering for additional options Switches shown in inactive posistion 46 PTO Interface PTO Interface ...

Page 50: ...o PTO and PTO DPST SW04 PTO Engage Relay 30 PTO Engage PTO Engage Relay 87 PTO PTO Power PTO Engage PTO PTO Ground Chassis GND PTO Ground PTO PTO Confirm PTO Confirm Relay 85 PTO Confirm Splice PTO Lamp LED L PTO Lamp LED L Chassis GND PTO Confirm PTO Confirm Relay 86 Chassis GND PTO Confirm Splice PTO Confirm Relay 30 PTO Confirm Relay 87 TCM B 16 PTO Confirm Connector B TCM mating end 20 10 19 9...

Page 51: ...r the PTO Active Switch It can be a mechanical ball switch or air switch Relay Isolated PTO Application 30 X Protected Power Battery or VIGN r Indicator Lamp Transmission ECU 38 Way Connector Vehicle Interface PTO Active Switches Battery Negative or Frame Ground 18 PTO Switch 19 Auto Neutral AW3 Switch Ground Additional PTO Active Switches PTO Active Switch 1 Transmission ECU 38 Way Connector Vehi...

Page 52: ...tor Lamp PTO Switch Input Vehicle 30 87a 87 86 85 30 87a 87 86 85 Transmission ECU 38 Way Connector Vehicle Interface PTO Active Switch 1 Battery Negative or Frame Ground 18 PTO Switch 19 Auto Neutral AW3 Switch Ground Additional PTO Active Switches 34 UltraShift PLUS Dual Switch PTO Application Transmission ECU 38 Way Connector Vehicle Interface 18 PTO Switch 19 Auto Neutral AW3 Switch Ground PTO...

Page 53: ...ft rotation for PTO engagement 4 Engage the PTO 5 Release clutch pedal 6 Raise engine speed up to operate the PTO Mobile PTO Operation The Transmission countershaft PTO is used in this application and provides limited mobile operation in the start gears To engage the PTO for mobile operation perform the following steps 1 Select N on the Shift Control 2 Apply the parking brake 3 Depress clutch full...

Page 54: ...ft Control 6 Release the service brake 7 Raise engine speed up minimum of 1000 RPM for heavy duty transmissions to operate the PTO Remote throttle controls are not approved for use with UltraShift ASW AW3 No required minimum engine speed for split shaft or countershaft PTO operation Mobile PTO Operation The Transmission countershaft PTO is used in this application and provides limited mobile opera...

Page 55: ...the engine speed as required to move vehicle operate PTO Split Shaft PTO Operation The drive line split shaft or transfer case PTO is used in this application and provides stationary operation only 1 With Vehicle stopped set the park brake and select Neutral 2 Press the service brake to disengage the clutch 3 Turn on the split shaft PTO switch The associated switch lamp should be on 4 It is critic...

Page 56: ...D on the Shift Control this stops countershaft rotation for PTO engagement 4 Engage the PTO 5 Select D MANUAL Neutral or Reverse as required for vehicle movement 6 Release the service brake to engage the clutch and the PTO 7 Raise the engine speed as required to move vehicle operate PTO Engine off Power Take Off ePTO Operation The ePTO provides standard hydraulic functions without continuous diese...

Page 57: ...torage position 2 Push ePTO button on shift console once to shut down electric power take off 3 Turn key to off position to shutdown vehicle or turn key to start position to start engine for driving Note Refer to Truck Equipment Manufacturer Body Company manuals for proper use of PTO tools and equipment Note The electric motor powering the ePTO is activated by a hydraulic demand signal generated b...

Page 58: ...o engage the clutch and power the PTO Mobile PTO Operation The Transmission countershaft PTO is used in this application and provides limited mobile operation in 2nd R2 only To engage the PTO for mobile operation perform the following steps 1 Apply the parking brake 2 Depress the service brake 3 PTO engagement must be made from neutral 4 Select N on the Shift Control 5 Engage the PTO 6 Release the...

Page 59: ...cie to clear frame and suspension components Both Chelsea and Muncie have produced adapters to rotate the HCIB away from potential vehicle interferences The Chelsea adapter kit is 630 2 30 degree The Muncie adapter kit is 40TF 6855 1 55 degree Prior experience has shown that only the Muncie 55 degree adapter works in the Kenworth T800 chassis specifically with set back front axles If ordering an U...

Page 60: ...s on the inertia brake casting If the transmission does not already have this style inertia brake a different kit containing the correct inertia brake needs to be ordered The correct inertia brake is required to keep the speed sensor pointing upwards to prevent oil leakage Items in kit 3 PTO Cover Gaskets 4305309 1 Jumper Harness 4306106 1 Harness Strap Bracket 4305794 4 Ty rap 5559348 1 Thread Se...

Page 61: ...me residual oil in the inertia brake 4 Remove the inertia brake spacer plate and gaskets from the transmission Note Clean and remove all old gasket material from the mating surfaces of the inertia brake and transmission PTO openings Note Some transmissions may not use a spacer plate with the inertia brake 5 Remove the 90º fitting and filter fitting from transmission case that was connected to the ...

Page 62: ...ome transmission models do not use a spacer with the inertia brake 2 Remove the Speed Sensor Adapter 3 Remove hex socket plug 4 Apply thread adhesive to the speed sensor adapter threads 5 Install the Speed Sensor adapter where the hex socket plug was Torque to 80 90 lb ft 108 122 Nm 6 Install hex socket plug where the speed sensor adapter was Torque to 80 90 lb ft 108 122 Nm Note When inertia brak...

Page 63: ...onnector Note Gently guide wires back into the Inertia Brake Housing Align connector screw holes with housing screw holes and insert connector into mounting hole Note orientation of Connector Use caution to prevent pinching of wires or damaging the o ring Reinstall 2 Screws and torque to 22 27 lb in 2 5 3 1 Nm 13 Apply thread adhesive to the screws and reinstall Torque to 1 84 2 28 lb ft 22 27 lb ...

Page 64: ...the transmission case Torque to 45 55 lb ft 61 75 Nm 2 Apply thread sealant to the 90º fitting Install into filter fitting Torque to 25 lb ft 34 Nm minimum then continue to rotate to position and orient upwards as shown 3 Install oil supply hose Connect the 45º end of the hose to the 90º fitting installed in the transmission Connect the 90º end of the hose to the 45º fitting on the inertia brake T...

Page 65: ...ly for electrical contacts 2 Route the jumper harness over the transmission with the correct connectors on the right side for the inertia brake and the correct connectors on the left side for the harness 3 Using the enclosed package of wire harness terminal lubricant nyogel lubricate the harness connectors using the fol lowing procedure Note The connector should be connected immediately after term...

Page 66: ...sure all connectors 2 on the right side 2 on the left side are fully mated and latches are locked 5 Tie down jumper harness with ty raps as shown below Note Do not over tighten ty raps Ty raps Ty raps Fill Transmission and Road Test 1 Fill transmission with synthetic transmission oil per Eaton publication TCMT 0021 Lubrication Manual 2 Look for leaks 3 Road test vehicle ...

Page 67: ... sure harness is connected and properly secured 5 Look for leaks and repair as necessary 6 Check the inertia brake for significant clearance to prevent contacting tanks brackets frame rails exhaust or any part of the vehicle If there is contact damage to the inertia brake could occur 7 If a PTO is installed instruct driver on PTO operation with an Ultrashift transmission Information can be found i...

Page 68: ... the six 6 mounting bolts from the 6 bolt PTO cover 8 Remove and discard the 6 bolt PTO cover and gasket from the transmission Note Clean and remove all old gasket material from the mating surfaces of the Inertia Brake and transmission PTO openings Locate the harness push in anchor point for reference during re installation to 6 bolt opening For spec ing or service assistance call 1 800 826 HELP 4...

Page 69: ...nertia Brake also requires a new lubrication hose Eaton part number 5588209 4 Using the six 6 3 8 mounting bolts install the Inertia Brake and gasket being careful to align the Inertia Brake gear with the drive gear Tighten mounting bolts to 40 45 lb ft 54 61 Nm using a cross pattern Note When mounted directly orient the inertia brake housing with hose connection forward electrical connection rear...

Page 70: ...brake housing Install tie wraps every 6 10 inches The harness should not have sharp bends or be under tension 7 Install the PTO to the 8 bolt PTO opening following the manufacturers instructions Note Fill the transmission with lubricant Final Check Make sure the mounting bolts are properly tightened Make sure the lubricant supply line is properly tightened Make sure the transmission is properly fi...

Page 71: ...ake when mounted to a PTO Angle Adapter Mate inertia brake connector and insert push in harness anchor into threaded hole as shown Route the harness up along side of the transmission case as indicated For installation without angle adapter use push in anchor and route harness up along case With either installation use a tie wrap at the top of transmission to remove excess slack Push in harness anc...

Page 72: ...ter plate and gasket from the transmission 7 Remove the six 6 mounting bolts from the 6 bolt PTO cover 8 Remove and discard the 6 bolt PTO cover and gasket from the transmission Note Clean and remove all old gasket material from the mating surfaces of the Inertia Brake and transmission PTO openings Locate the harness push in anchor point for reference during re installation to 6 bolt opening For s...

Page 73: ...Note When mounted directly orient the inertia brake housing with hose connection forward electrical connection rearward as shown in the Final Check section same orientation as 8 bolt When mounted to a 6 bolt PTO Angle Adapter orient the inertia brake housing with hose connection rearward electrical connection forward as shown in the illustration in the Final Check section Ensure gasket inertia bra...

Page 74: ... bolt PTO opening following the manufacturers instructions Note Fill the transmission with lubricant Final Check Make sure the mounting bolts are properly tightened Make sure the lubricant supply line is properly tightened Make sure the transmission is properly filled with lubricant Make sure the Transmission Harness is connected and locked Check for lubricant leaks after operating the vehicle Che...

Page 75: ...structions above for installation without angle adaptor Inertia Brake mounting to 6 bolt Angle Adapter as viewed from rear of transmission Note orientation of hose connection end of Inertia Brake when mounted to a PTO Angle Adapter 72 Inertia Brake Inertia Brake ...

Page 76: ...cover end of terminal Fold package length wise Before starting inspect mating connector pins on transmission for damage or dirt If pins need cleaning use clean shop air or an approved spray cleaner specifically for electrical contacts To ease dispensing fold and cut package as shown above Dispensing a small amount of lubricant onto each terminal of harness The amount should be just enough to cover...

Page 77: ...the harness up along side of the transmission case as indicated With any installation scheme use tie wraps at the top and side of transmission to remove excess slack 3 Push in Anchor 1 2 3 1 2 Route the harness along rear of X Y Controller as shown Attach connector to Transmission harness Add additional tie wraps to adequately secure harness 4 Tie Wrap to harness 5 Connector 6 X Y Controller 4 4 5...

Page 78: ...anufacturers Contact Information Chelsea Products Division 8225 Hacks Cross Road Olive Branch MS 38654 662 895 1011 www parker com chelsea Muncie Power Products Inc P O Box 548 Muncie IN 47308 0548 765 284 7721 www munciepower com ...

Page 79: ...nsmission RT Linehaul Heavy Duty Manual Transmission RT Vocational Heavy Duty Manual Transmission RT Performance Heavy Duty Manual Transmission FR Series Heavy Duty Manual Transmission Auxiliary Transmission Heavy Duty Automated 10 Speed Heavy Duty Automated UltraShift PLUS VCS and VMS Heavy Duty Automated 13 18 16 Speed March 2013 Added UltraShift PLUS LSE Model PTO information UltraShift PLUS PT...

Page 80: ...cs by adding 34 UltraShift PLUS to each of the grounds Medium Duty and Heavy Duty Automated PTO Operating Instructions section AutoShift Countershaft and Split Shaft PTO Operation section Changed Item 4 from Select the transmission PTO switch to Engage PTO Mobile PTO Operation section Changed item 4 from Select the transmission PTO switch to Engage PTO UltraShift Countershaft PTO Operation section...

Page 81: ...ypo in call the model name for Heavy Duty Automated 13 18 Speed table for Model FO 16E318B MXP Added to Heavy Duty Automated UltraShift PLUS VCS and VMS table the following Models FO 18E313A VHP FO 20E313A VHP Added last note on Inertia Break Relocate Section December 2009 Added K 3834 to UltraShift PLUS PTO pin out configuration notes Updated and changed the PTO operation instructions for all aut...

Page 82: ...oducts with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www ...

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Eaton AT-1202, Installation Manual

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