Eaton Roadranger Fuller UltraShift F-406-ASW Series Installation Manual Download | Manualshive

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Introduction

About This Publication

This Eaton publication is intended to be a reference guide for the installation of the Fuller® Fx-x406x-ASW UltraShift™ Transmis-
sion. General vehicle and transmission information is provided to cover 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 additional transmission information, see the Suggested Tools section in the back of this manual. For specific engine
information contact the engine OEM.

Failure to adhere to Eaton Installation Requirements may affect transmission performance and/or warranty coverage.

Fuller UltraShift ASW

are compatible with electronically governed engines equipped with a J-1939 data link and certified by Eaton

Corporation. Transmissions installed at OEM facilities must meet and be approved by Eaton Application Engineering. Contact
Eaton Application Engineering or your OEM Application Engineering department for proper Application form. All applications
must be submitted for approval.

OEM facilities must submit a design package to Eaton Corporation OEM Engineering Support Group for approval prior to any
OEM build. A design package consist of the following information.

Electrical Systems

Wiring Schematic: This should show how the Fuller UltraShift ASW would interface with the vehicle.

Individual Harness Drawings: This should show the construction of each harness.

Harness Routings: This should show how each harness is routed in the vehicle. The locations of relays, fuses, power connec-
tions, tie-downs, etc.

Fuller UltraShift ASW Cooling System

Cooler size/type

Cooler line routing

Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation
makes no warranty, either expressed or implied, based on the information provided. With each new application, engine manufac-
tures should be contacted to make sure desired engines are compatible with the Fuller UltraShift ASW systems.

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Summary of Contents for Roadranger Fuller UltraShift F-406-ASW Series

Page 1: ...Fuller AutomatedTransmissions Installation Guide Fuller Automated Transmissions TRIG0082 October 2007 More time on the road ...

Page 2: ...This page intentionally left blank ...

Page 3: ...Gear Display Module 35 Ignition Circuit Detail 37 J 1587 Diagnostic Detail 38 Dimmer Control Input Connection 40 Typical Start Enable Circuit 41 J 1939 Data Link Detail 43 Vehicle Harness Connector for all Caterpillar Adam III Electronic Engines 50 Body Builder Guide For Tapping into Electrical Systems 53 Features Inside Cab Features 55 Outside Cab Features 56 Auto Neutral Feature 57 Power Take Of...

Page 4: ...ication Engineering Contact Eaton Application Engineering or your OEM Application Engineering department for proper Application form All applications must be submitted for approval OEM facilities must submit a design package to Eaton Corporation OEM Engineering Support Group for approval prior to any OEM build A design package consist of the following information Electrical Systems Wiring Schemati...

Page 5: ...ly available VOM Eaton Corporation OEM Engineering Support Group TBD Pull to Neutral Box 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 1 800 826 4357 Part No Description MD 200 Related Publications Troubleshooting Guide Eaton TRTS 0062 Service Manual Eaton TRSM 0062 Driver I...

Page 6: ... shall be a minimum of 16 gauge 1 0 mm The cable inside the cab shall be a min imum of 18 gauge 0 8 mm When the Eaton Push Button Shift Control is used the EPL the communications link between the Shift Control and the Transmission Controller must be a twisted shielded pair Belden J 1939 or equivalent The J 1939 the communications link between the Shift Control and the Engine Controller ECM must fo...

Page 7: ...Systems installed at OEM plants the engine ECU must contain the proper configuration settings For the proper engine configuration settings required for Eaton Transmission operation contact Eaton OEM Engineering Support Group E x h a u s t P i p e 4 This area must be left clear of all wires and hoses for serviceability ...

Page 8: ...oler lines must be flushed or cleaned A minimum of 12 3 4 inch I D cooler hose or comparable tubing must be used Dipstick and Dipstick Tube Requirements 1 Dipstick New dipstick and tube designs are required to be approved and or validated by Eaton as supplied by the OEM 2 Support Bracket A supporting bracket to eliminate vibration is required at the upper end of the dipstick tube The bracket must ...

Page 9: ... 8 93 248 1 248 1 11 18 11 18 213 2 213 2 8 40 8 40 83 30 83 30 7 217 7 217 240 2 240 2 9 46 9 46 240 2 240 2 9 46 9 46 OIL FILL TUBE OEM SUPPLIED OIL FILL TUBE OEM SUPPLIED FOR WET CLUTCH SECTION FOR WET CLUTCH SECTION 1 5 16 12 UN 2A FOR 1 5 16 12 UN 2A FOR 37 FLARED TUBE FITTING 37 FLARED TUBE FITTING 274 1 274 1 10 79 10 79 ...

Page 10: ...7 Installation Requirements Fuller UltraShift ASW FO x406x ASW 98 43 3 875 20 6 0 81 ...

Page 11: ...e OEM specifications for concentricity Refer to engine specifications for runout lim its 3 Install the flywheel onto the engine crankshaft using the hardware and mounting specifications of the engine manufac turer 4 Input shaft pilot bearing is required Install pilot bearing 5 Drive Coupler alignment tool must be used when installing Drive Coupler contact your Eaton Liaison Engineer for align ment...

Page 12: ...ning any capscrews Do not use the capscrews to seat the housing 6 Tighten four mounting capscrews at 90 intervals around the clutch housing then tighten the remaining trans mission mounting capscrews using the recommended torque specifications Note Do not tighten any mounting capscrews until all capscrews have been installed finger tight Do not remove the transmission support chain or jack until a...

Page 13: ...on Requirements Transmission Mounting Typical Lift Points TRANSMISSION LIFTING EYES 3 POINT LIFT CHAIN WITH MINIMUM 1 TON CAPACITY TO CLU TCH LIF TIN G EYE T O C L U T C H L I F T I N G E Y E 5 POINT LIFTING CHAIN WITH MINIMUM 2 TON CAPACITY ...

Page 14: ...tion of the dipstick tube must be vertical from the oil pan connector a minimum of 2 5 above the clutch housing oil pan mounting surface to insure accurate level readings 5 Horizontal or near horizontal runs sharp tight and excessive bends are prohibited in the tube design as they adversely affect oil fill time and accurate level readings 6 Torque dipstick tube fitting 1 5 8 12 to 60 70 lbs ft 81 ...

Page 15: ...st remain vertical for a minimum of 2 5 inches from the end of the fill tube Note A ball end or some equivalent is recommended on the dipstick to prevent interference with tube mounting Note All fluid levels are measured with the system operating in neutral 64 0 2 52 35 6 1 40 15 2 0 60 Cold FULL Level Cold ADD Level Approx 1 quart ...

Page 16: ...oil flow at 6 gallons per minute 6 A minimum heat extraction rate of 700 BTU minute is required for most applications A minimum heat extrac tion rate of 1 000 BTU minute is required for severe applications 7 A minimum SAE 12 3 4 inch cooler hose or comparable tubing must be used for the Fuller UltraShift ASW transmission cooler circuit 8 The oil cooler and cooler lines should be free of debris dir...

Page 17: ...R TO WATER PUMP WATER TO COOLER OIL FROM COOLER TO TRANSMISSION OIL COOLER MINIMUM 12 RECOMMENDED WC OUT TO OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED WC IN FROM OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED THERMOSTAT OIL COOLER T C COOLER PUMP RADIATOR LINERS and HEADS ...

Page 18: ...e conditions which may require the use of a thermostat bypass 1 Under certain conditions such as extreme cold temperature operation or extended periods of low speed oper ation the engine alone may not generate the amount of heat required to open the thermostat Without a ther mal bypass system no cooling is provided for the transmission under these conditions 2 The thermal bypass system will provid...

Page 19: ...ER PUMP WATER TO COOLER OIL FROM COOLER TO TRANSMISSION OIL COOLER MINIMUM 12 RECOMMENDED WC OUT TO OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED WC IN FROM OIL COOLER 1 1 16 12 UN 2B FOR SAE 12 O RING FITTING 37 DEGREE FLARED FITTING OEM SUPPLIED THERMOSTAT OIL COOLER T C COOLER PUMP RADIATOR REMOTE BYPASS LINERS and HEADS ...

Page 20: ...ays be within the operating marks on the dipstick The exact amount of oil depends on the transmission inclination and cooling system capacity 6 Insufficient oil damages the pump and other components and can affect the function and reduce the life of the transmission Note DO NOT OVERFILL This causes foaming overheating loss of fuel economy and possibly not shifting 7 When adding oil types and brand...

Page 21: ...ubricant circulated by the motion of gears and shafts Thus all parts will be amply lubricated if these procedures are closely followed 1 Use Roadranger CD 50 or equivalent synthetic per Eaton publication TCMT 0019 2 When adding lubricant types and brands of lubricant should not be mixed because of possible incompatibility 3 Use clean lubricant and containers when filling the transmission Container...

Page 22: ...r X Y Shifter at any time Lubrication Change and Inspection HIGHWAY USE First 1 000 to 1 500 miles Inspect oil levels Check for leaks Every 2 500 miles Inspect oil levels Check for oil leaks Every 150 000 miles or every three 3 years Change transmission gear box oil Change WetClutch oil and filters Recommended Lubricant Type WetClutch Synthetic Dexron III Transmission Main Case Roadranger CD50 Imp...

Page 23: ...0 way 2 Body 12048455 3 Terminal 12103881 10 16 0 400 32 21 1 268 57 28 2 255 101 98 4 015 165 10 6 500 172 72 6 800 22 86 0 900 39 75 1 565 38 10 1 500 76 20 3 000 83 82 3 300 22 23 0 875 27 00 1 063 168 15 6 56 PANEL CUT OUT DIMENSIONS 4X R 10 MAX 79 25 3 06 SERVICE SHIFT EATON FULLER TRANSMISSIONS LOW MANUAL D N R 2X 8 32 UNC ...

Page 24: ...upplied mounting bezel If no bezel is used the OEM must ensure the Shift Control is accessible to the driver at all times 3 A cab floor transmission access plate is necessary to service components on the top of the transmission See Installation Requirements on page 3 for details DASH Easily accessible and removable transmission access plate Note The driver must be able to see and use the shift con...

Page 25: ... reach of the driver s normal position Note The driver must be able to see and use the Shift Control at all times 4 The Shift Control assembly should not interfere with other vehicle related controls or features 5 If the shift tower is not mounted on a removable plate an access floor plate is necessary to service compo nents on top of the transmission See Installation Requirements on page 3 for de...

Page 26: ...pling positive lock or bolt together style Packard Delphi 280 Series or equivalent should be used when possible Connectors shall have the capability of being probed by a commercially available volt ohm meter without being damaged Sealed Connectors Sealed connectors shall be required outside the cab environment The connector seal shall not come off when removing a connector from its mate Cable seal...

Page 27: ...oom Mesh Coverage A minimum of 10 maximum of 12 picks per inch The braid shall be woven so as to produce a tight non slip covering over the cables The braid shall be heat sealed to prevent unraveling Braid must have a minimum service tem perature of 280 F 138 C Insulating Sleeves Sleeves shall be constructed of a heat shrinkable irradiated adhesive lined semi rigid polyolefin The color shall be bl...

Page 28: ...ive weld is also an approved method for splicing Splices shall be insulated with 2 inch long heat shrinkable tubing Circuit Identification Circuit identification shall be by either numbers letters or color coding When numbers letters are used coding shall be applied continuously along the length in approximately two to three inch increments Code shall be visible at breakouts When color coding is u...

Page 29: ...nition power switched power run to main power lead that feeds the ignition bus 10 AMP 12 volt only automatic resetting circuit breaker 10 or 15 AMP fuse Or A B C D E F J 1587 data link E1 E2 E3 C1 B2 C2 A2 C3 A3 B3 30 87 86 85 30 86 87 85 B F G A 6 way 9 way 30 AMP fuse Battery power Non switched power run to starter or Battery Terminating resistor Bulkhead connector located at firewall C1 C2 C3 A...

Page 30: ...60 70 80 90 100 MPH KPH C A B E A B C D E F Dimmer Control Input Start Enable Relay Firewall Floor Board ATA Connector J1587 Link Transmission Interface Harness Vehicle Interface Harness Terminating Resistor Terminating Resistor J1939 Data Link OEM supplied Engine ECM Engine Power Leads to Starter Ignition Power Switched Power 10 AMP 12 Volt only Automatic Resetting Circuit Breaker 10 AMP Fuse or ...

Page 31: ... RPM 0 10 20 30 40 50 60 70 80 90 100 MPH KPH C A B E A B C D E F Dimmer Control Input Start Enable Relay Firewall Floor Board ATA Connector J1587 Link Transmission Interface Harness Vehicle Interface Harness Transmission Interface Harness Terminating Resistor Terminating Resistor J1939 Data Link OEM supplied Engine ECM Engine Power Leads to Starter Ignition Power Switched Power 10 AMP 12 Volt onl...

Page 32: ... Harness is four foot long made of 12 AWG 3 0mm which equals 0016 ohms per foot 12 vdc and ground wires combined equals 8 feet 203mm The Main Power connector is connected to the starter which equals six connections According to the Delphi Packard Electrical Systems each connector is 005 ohms 1 8ft 0016 ohms 013 ohms 2 6 connectors 005 ohms 03 ohms 3 03 013 043 ohms For this example the total resis...

Page 33: ...red reliable battery sources FROM TO WIRE DESCRIPTION J3 A T2 Ground J3 B J2 B 12 Volts J2 A T1 Battery J2 PACKARD BODY 12020341 CONNECTOR SEAL 12077383 TERMINAL 12033997 10 12 AWG CAP 12033731 CABLE SEAL 12040972 12 AWG 12085024 10 AWG 30 AMP Fuse In Line Fuse PACKARD BODY 12059641 CONNECTOR SEAL 12077383 TERMINAL 12033997 10 12 AWG CABLE SEAL 12040972 12 AWG 12085024 10 AWG T1 connects to the si...

Page 34: ...on Shift Control Push Button Control 30 way connector J1939 Data Link A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 B2 C2 J3 K3 A2 C1 C3 D1 D2 D3 E3 B2 C2 F1 F2 F3 A3 B3 E1 E2 A1 B1 J1 J2 K1 K2 FRONT VIEW Push Button Control 30 Way Connector FRONT VIEW Transmission 18 Way Connector PACKARD Connector 12040921 Terminal 12103881 Plug 12034413 PACKARD Connector 12048455 Terminal 12...

Page 35: ... 1939 Green J1 J3 J2 A3 GND 1 J1 G3 J3 C J 1939 Shield To Dash Components Push Button Control 30 Way Connector Bulkhead Connector Located at Firewall J1 J1939 Data Link EPL Data Link EPL EPL_Shield EPL EPL EPL_Shield EPL Firewall PACKARD Connector 12040921 Terminal 12103881 Plug 12034413 PACKARD Connector 12048455 Terminal 12103881 Plug 12034413 Transmission 18 Way Connector J1587 Data Link J1587 ...

Page 36: ...to start signal from igntion switch Run to starter solenoid Ignition power switched power run to main power lead that feeds the ignition bus 10 AMP 12 volt only automatic resetting circuit breaker 10 or 15 AMP fuse Or A B C D E F J 1587 data link E1 E2 E3 C1 B2 C2 A2 C3 A3 B3 30 87 86 85 30 86 87 85 B F G A 6 way 9 way Push Button Shift Control Push Button Control 30 way connector A F J E G H D C ...

Page 37: ...A J1587 6 pin J1 C2 J4 B J1587 6 pin J1 B3 J5 DIMMER CONTROL J1 C3 J6 85 START ENABLE RELAY J1 A3 J6 86 START ENABLE RELAY J1 A2 J6 87 START ENABLE RELAY LATCH J6 87 SPLICE STARTER SOLENOID J1 Push Button Control 30 wat Connector Packard Connector 12048455 Terminal 12103881 Plug 12034413 Firewall Run to start signal from igntion switch Run to starter Solenoid J6 J5 Dimmer Control J3 Switched Ignit...

Page 38: ...AY POWER J1 E3 J2 4 DISPLAY POWER Truck Components 1 2 3 4 EATON P N 4302640 Top View Pin 4 Pin 1 A1 A2 A3 B1 B2 B3 C2 C3 D1 D2 D3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 FRONT VIEW Shift Control 30 Way Connector C1 E1 E2 E3 Gear display 1 2 3 4 Ignition power switched power E1 E2 E3 C1 Push Button Shift Control Push Button Control 30 way connector J2 J1 ...

Page 39: ... Display Module Panel Cut Out Dimensions 43 1 1 70 X 56 1 2 20 X 0 254 010 Mating Connector information AMP 4 way Body 1 480702 0 Terminal 350551 2 Truck Components 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 ...

Page 40: ...olt only automatic resetting circuit breaker 10 AMP fuse Or C1 Push Button Shift Control Push Button Control 30 way connector J1 Ignition Power Switched Power Run to Main Power lead that feeds the Ignition Bus To Shift Control and Gear Display A1 A2 A3 B1 B3 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 B2 C2 C1 FRONT VIEW Shift Control 30 Way Connector 10 AMP 12 volt only auto...

Page 41: ...trical Requirements J 1587 Diagnostic Link C A B E 12 volts battery For transmission diagnostics A B C D E F J 1587 data link B2 C2 B F G A 6 way 9 way Push Button Shift Control Push Button Control 30 way connector A F J E G H D C B ...

Page 42: ...IPTION J1 B2 A F ATA J1 C2 B G ATA __ C B BATTERY __ E A GROUND J1 G1 __ C J 1939 J1 G2 __ D J 1939 J1 G3 __ E J 1939 shield ATA ATA A B C D E F A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 C2 H1 H2 H3 J1 J2 J3 K1 K2 K3 FRONT VIEW Shift Control 30 Way Connector B2 C2 ATA ATA J C D E F G H A B C A B E 12 Volts VIEW A A A A A B 12 Volts B B F G VIEW B B J1 G2 G1 G3 ...

Page 43: ...on When VDASH input is off the lights on the Shift Control will be on full FROM TO J1 B3 VDASH Back side of gauges Dash lights B3 Push Button Shift Control Push Button Control 30 way connector Dimmer Control Input To Shift Control Dimmer Control Back of Dash Gauges Dash Lights A1 A2 A3 B1 B2 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3 B3 FRONT VIEW Shift Control 30 Way ...

Page 44: ...n 3 1 3 The engine starter shall be inoperative when the transmission shift lever is in a forward or reverse direction position Start enable relay Run to start signal from igntion switch Run to starter solenoid A2 C3 A3 30 87 86 85 30 86 87 85 Push Button Shift Control Push Button Control 30 way connector ...

Page 45: ... Run to Starter Solenoid 85 30 86 87a 87 Start Enable Battery C3 Run to Starter Solenoid Run to Start Post of Ignition Switch BATT KEY SWITCH ACC OFF IGNITION KEY START If Used Relay Coil Relay N O Start Enable Battery STARTER SOLENOID Relay Schematic Start Enable Latch A2 Start Enable Ground Start Enable Ground A3 Start Enable Latch A2 Run to Start Enable Latch A2 Start Enable Ground A3 PUSH BUTT...

Page 46: ...9 Data Link Terminating resistor J 1939 11 data link OEM supplied GND _ Shield termination Engine ECM Terminating resistor Bulkhead connector located at firewall G1 G2 G3 Push Button Shift Control Push Button Control 30 way connector ...

Page 47: ...nts J 1939 Data Link Detail FROM TO DESCRIPTION J1 G1 A J 1939 High J1 G2 B J 1939 Low J1 G3 C J 1939 Shield A1 A2 A3 B1 B3 C1 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 H1 H2 H3 FRONT VIEW Shift Control 30 Way Connector B2 C2 J3 K3 J1 J2 K1 K2 G1 G2 G3 B A C J1 ...

Page 48: ... 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 Termination 16 Gage GXL Recommended Cable Manufacturer Cable Part Number Round J 1939 PIN A Co...

Page 49: ...re on the solder sleeve to a length of 25 mm and strip the insulation back 7 mm Crimp the appropriate terminal on each data wire and solder sleeve wire or the extended socket per the manufacturer s recommendations Slide an adhesive filler shrink tube over the cable end Install the terminals into the connector body per the manufacturer s instructions Install the wedge in the front of the connector ...

Page 50: ...m exposed wires to within 2 mm from cable jacket Strip insulation from data wires 7 mm 0 8 mm Crimp stub branch lines and drain wire to main backbone data lines and drain wire Cover each splice with insulation shrink tubing Wrap unshielded area with shielding material Apply adhesive filled shrink tube to splice junction For shield termination crimp minimum 16 gauge GXL wire to drain wire ...

Page 51: ... to within 2 mm from cable jacket Strip insulation from data wires 7 mm 0 8 mm Attach X link wire to drain wire with crimp splice per manufacturer s recommendation Slide adhesive filled shrink tube over crimp splice Slide adhesive filled shrink tube over cable end Shrink Tube Cross Link Drain Wire Shrink Tube Cable Crimp Data Wires Cable Shrink Tube Drain Wire Data Wires Final Assembly ...

Page 52: ...t per inch 120 Ohm terminating resistors must be used Connector at ECU is not defined The third pin for shield is not used in in line and T connectors Recommended Cable Manufacturer Cable Part Number Round J 1939 PIN A Color J 1939 PIN B Color Champlain J1939 15 Yes Yellow Green Twisted Pair J1939 J1939 J1939 ECU 1 ECU 2 Terminating Resistor 120 ohms Terminating Resistor 120 ohms J1939 ...

Page 53: ...n in this manual for connector information FROM DESCRIPTION P1 50 J 1939 High P1 34 J 1939 Low P 42 J 1939 Shield PEI 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 39 40 41 43 44 45 46 47 48 49 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 34 42 50 View From Harness Side of Connector P1 ...

Page 54: ...39 Control Data Link on Detroit Diesel DDECIII and IV Engines FROM TO DESCRIPTION K1 F K4 A J 1939 High K1 E K4 B J 1939 Low K1 D K4 C J 1939 Shield J 1939 SHIELD J 1939 J 1939 F E D C B A K4 K1 Electronic Control Module ECM Communication Connector ...

Page 55: ... Interface Harness J 1939 3 pin Deutch connector will already be present No additional con nections are needed to connect the engine ECM to the J 1939 backbone Note It may be necessary to extract the connector from behind a bracket located at the rear of the engine Simply push the connector out from behind the bracket Engine ECM Engine ...

Page 56: ...ting wiring into wheel splash areas should be avoided When such routing cannot be avoided adequate clipping or protective shielding is required to protect wiring from stone and ice damage 8 Routing wires under the frame side members or at points lower than the bottom frame flange should be avoided to pre vent damage to the wires in off road operations 9 The wire retainers and grommets installed by...

Page 57: ...rrect gauge Failure to adopt this precaution will lead to switch contacts burning The following wire table suggest wire gauges for various maximum current draws and will aid in the selection of the correct wire size The current capacity of a given wire varies with temperature and type of insulation but the following val ues are generally acceptable If the total electrical load on the circuit after...

Page 58: ...s FROM TO Description J1 A1 J2 A Auto Neutral Input J1 B1 J2 C Auto Neutral Return J1 H1 J2 E Quick to Neutral Return J1 H3 J2 F Quick to Neutral Input A1 B1 H1 H3 A C E F J1 J2 PACKARD Body 12064752 Terminal 12162595 Lock 12064753 ...

Page 59: ...nection Table FROM TO Description J3 D3 J4 A Aux 1 Input J3 E3 J4 B Aux 1 Input Return J3 F3 J4 C Aux 1 Output Lo side J3 F1 J4 D PTO Input J3 F2 J4 E PTO Input Return D3 E3 F3 F1 F2 PACKARD Body 12129325 Terminal 12077411 Lock 12015323 J3 J4 A B E D C ...

Page 60: ...stationary PTO operation and a transmission gear engagement cannot be selected When disengaged switch opened normal transmission gear engagement can be selected The Fuller UltraShift 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 Interconnection Table From To Wire Description A1 Switch Auto Neu...

Page 61: ...ssion 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 pro grammed for something other than countershaft PTO...

Page 62: ...ngaged for split shaft PTO operation The transmission default mode for the pin F1 input is for countershaft PTO operation if split shaft PTO operation is desired the PC based service tool ServiceRanger must be used to enable split shaft PTO feature The input signal wire for the PTO must be isolated from other PTO related circuits NOTE The input signal wire for the PTO must be isolated from other P...

Page 63: ...necessary corrective action prior to dyno or road testing 4 The DYNO ROAD TEST section is used to verify that all transmission systems are functional the clutch is cali brated properly and the driver information is supplied in the cab 5 With a record of transmission related information and repairs made to each unit the OEM is able to track and correct repeated quality issues 6 A copy of the checkl...

Page 64: ...tomatically provides for clutch wear The system will initiate a clutch calibration once per each vehi cle power up when certain vehicle conditions are right Of these conditions the most important ones are the engine is running at idle speed at its normal operating temperature the vehicle is stopped and neutral is selected on the Shift Console During the calibration the clutch is partially engaged ...

Page 65: ...hen driving the problem is that the dynamometer decelerates too quickly 7 Verify through normal operation that the engine brake if equipped functions correctly per the manufacturer s specifications 8 Verify that the panel lights on the Shift Control illuminate when the vehicle dash lights are turned on 9 Visually check for lubricant drips or residue on the transmission and related cooler lines if ...

Page 66: ...ting with the transmission in gear Failure to preform installation pre start checks may result in the engine cranking immediately when ignition is moved to the START position or to the ON position To prevent undesired vehicle movement for new installations always set the parking brake prior to turning the ignition key ON and also prior to attempting START ...

Page 67: ...mperature gauge is functional if equipped 7 Verify gear display module DDM works correctly 8 Shift Control panel lights functional 9 Verify no transmission oil leaks 10 Transmission diagnostic port accessible 11 Lubricant type and brand label affixed to vehicle 12 Check for dash label 13 Check for correct engine brake operation 14 Clear Fault Codes and Verify J 1587 Diagnostic Connector works 15 P...

Page 68: ...Guide for flash code retrieval If dash is still on the gear display then power down turn the key off and wait for one minute and power up Verify Start Enable Relay circuit is installed correctly Verify contacts are connected correctly in the safety neutral circuit Resume operation Call OEM Service Support 800 826 HELP Service Light on Solid or Flashing No No No No Yes Yes Yes Yes ...

Page 69: ...nectors Electronic Shifter Transmission Controller Transmission To Vehicle Interface Harnesses Transmission Power Supply Harness from Start Battery Source Transmission Interface Harness Vehicle Interface Harness J 1939 Connector OEM Interface Connector Diagnostic Port SAE J 1587 Accessible in cab Gear Display Visable At All Times Tower Mounted Shift Console Firewall Connector for Cab Connections ...

Page 70: ...ansmission Controller Transmission To Vehicle Interface Harnesses Transmission Power Supply Harness from Start Battery Source OEM Interface Connector J 1939 Connector Firewall Connector for Cab Connections SERVICE SHIFT EATON FULLER TRANSMISSIONS LOW MANUAL D N R Dash Mounted Shift Console Diagnostic Port SAE J 1587 Accessible in cab Gear Display Visable At All Times ...

Page 71: ...or Position Fx x406x ASW Note Bolts used for retaining sensors or lifting eyes are not to be used for any other purpose or have any other brackets attached to them Lifting Eye 12 O Clock output Shaft Speed Sensor 10 O Clock Output Shaft Speed Sensor Lifting Eye ...

Page 72: ...ampcable com DEUTSCH Connectors Industrial Products Division 37140 Industrial Ave Hemet CA 92545 909 765 2250 Fax 909 765 2255 www deutschipd com www laddinc com Ladd Industries PACKARD Electric Connectors Pioneer Standard Electronics Inc Packard Branch 5440 Naiman Parkway Solon OH 44139 1 800 PARKARD 722 5273 Fax 219 378 6650 www delphiconnect com RAYCHEM Wire Electronics OEM Components Division ...

Page 73: ...required in WetClutch section of transmission Eaton Roadranger CD50 or equivalent required in transmission gear box Electrical Section Electrical Dual Power required Main Power and ground must be connected to reliable power and ground source Frame rails and splices into other har nesses are not considered reliable battery sources OEM to supply main vehicle harness Dash to shift control and transmi...

Page 74: ...ting per Eaton approval OEM is responsible for rigidly mounting the shift control pedestal Access plate on the floor board is easily removable Sealed connectors required at shift control pedestal on conventional cabs Gear Display Module supplied by Eaton Digital display mounts in dash to provide driver information ...

Page 75: ...b ft 27 34 Nm Reverse switch 9 16 18 20 25 Lb ft 27 34 Nm Neutral switch cap 3 4 16 20 25 Lb ft 27 34 Nm ECU Connector Bolt 20 30 Lb in 2 25 3 39 Nm Lubricant fill plug 6 Speed 3 4 NPT 45 55 Lb ft 61 75 Nm Lifting bracket capscrew 3 8 16 35 45 Lb ft 47 61 Nm Rear bearing cover capscrew 3 8 16 35 40 Lb ft 47 55 Nm Rear bearing cover nut 1 2 20 60 70 Lb ft 81 95 Nm Oil cooler line fitting 50 60 Lb f...

Page 76: ...D1 D2 H1 H2 K2 K3 J2 J3 C1 C2 C3 A1 A3 B1 E2 B3 E1 Terminating resistor J1 J2 J3 A B C A B C EPL data link Bulkhead connector located at firewall Gear select motor Rail select motor Electric shifter Aux 1 Output see OEM for wiring diagrams and correct operation Aux 1 Input see OEM for wiring diagrams and correct operation F3 F1 F2 Hydraulic manifold Assembly 3 3 4 4 1 1 2 2 Fuller UltraShift ASW W...

Page 77: ... side of gauges Dash lights Dimmer control input C A B E 12 volts battery For transmission diagnostics Start enable relay Run to start signal from ignition switch Run to starter solenoid Ignition power switched power run to main power lead that feeds the ignition bus 10 AMP 12 volt only automatic resetting circuit breaker 10 AMP fuse Or A B C D E F J 1587 data link E1 E2 E3 C1 B2 C2 A2 C3 A3 B3 30...

Page 78: ...WAY DESCRIPTION NOTES A1 Batt 1 A2 ATA A3 GND 1 B1 Trans batt 1 B2 ATA B3 GND 2 C1 EPL C2 EPL C3 EPL shield D1 Aux speed 1 D2 Aux speed 1 D3 Aux input 2 Input LO side E1 Batt 2 E2 Trans batt 2 E3 Aux input 2 Return F1 Aux input 1 Input LO side F2 Aux input 1 Return F3 Aux output 1 Output LO side driver ...

Page 79: ...Ignition C2 1587 C3 Start enable relay D1 Aux input 5 Input LO side D2 Aux input 6 Input LO side D3 Aux output 3 Output LO side driver E1 Gear display clock E2 Gear display data E3 Gear display Return F1 EPL F2 EPL F3 EPL shield G1 1939 G2 1939 G3 1939 shield H1 Aux input 6 Return H2 Aux output 2 Output HI LO side driver H3 Aux input output 4 Input output LO side driver J1 Batt 1 J2 Trans batt 1 J...

Page 80: ...er trusted partners providing the best products and services in the industry ensuring more time on the road 20 07 Eaton Corporation All rights reserved Printed in US A Copyright Eaton and Dana Corporation 2007 EATON AND DANA CORPORA TION hereby grants its customer s vendor s or distributor s permission to freely copy reproduce and or distribute this document inprintedformat Itmaybecopiedonlyinits ...

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